2022 GRAND DESIGN REFLECTION Structure Problems

The contact owns a 2022 Grand Design Recreational Reflection RV. The contact stated that while driving approximately 60 MPH, the propane compartment doors opened unintendedly. The failure had occurred on several occasions. The contact stated that the roof was peeling and cracking and the contact was concerned that there were signs of frame flex, and that the walls were unstable and there were other structural failures. No warning lights were illuminated. The RV was taken to the residence and was not yet diagnosed or repaired. The failure mileage was unknown.

After the trailer collapsed, I’m deeply concerned for my children’s safety and the safety of others. Despite raising these issues, the manufacture Grand Design has deflected responsibility and refused to act, even while under warranty. I kindly request immediate attention and a formal response. I previously brought it to Grand Design in Elkhart, Indiana while it was under warranty, but they declined both inspection and repair. I am really struggling with why RVs are not federally regulated. My trailer poses serious safety risks to my family and others on the road due to the following issues: 1) Frame and Structural Failures: - Trailer collapsed when the frame broke holding the jacks - Welds breaking - Possible I-beam twisted (still need to confirm though) - Screws falling out while driving; risk of tire puncture and skirt/fender detachment - Driver-side outer wall separating from inner wall (gap large enough to fit a hand) - Main doors and cargo doors not staying closed during transport - Floor sinking in kitchen and bunk room - Trim detaching; walls bowing outward - Walls trimmed short five times, due to walls sinking with the floors from weight of roof - Severed screw heads on driver-side slides from excessive frame flex - Bathroom and hallway walls bowing - Sawdust on floor after each move - Master bedroom door damaged from wall bowing 2) Safety Concerns: - Brake breakaway system failed (now repaired) - Propane leaks - Wheel loose and balding due to improperly set crown bolt - Smoke and carbon monoxide detectors missing in bedrooms - Water pipes leaking onto electrical wiring (potential electrocution and/or fire) - Breaker box improperly wired (fire concerns) - Grounding issues affecting AC display and tank readers - Fridge leaking water inside (concerned about black mold) - Front jacks uneven and unstable and other issues too.

1. EXCESSIVE FRAME FLEX / FAILURE: Symptoms include: Bowing of walls; Trim coming loose; Cracks in fiberglass wall by slide (occurred a 2nd time after side wall repaired by factory) ; crack in interior wall; crack in roof; Main door opening during transport; Sawdust repeatedly appearing in cabinets; Failure of the attachment point between the frame and walls 2. STRUCTURAL ISSUES: Slide repaired twice at the factory and currently under warranty repair by dealership for a 3rd instance 3. Repairs done at factory in IN documents issues with both Grand Design and dealership acknowledging the failures were covered by warranty. 4. Inspected by both GD factory & dealership with documented failures falling under the warranty NOTE: Too many emails between Grand Design cust service and McClain's dealership to attach; working to put them all in a single PDF to send.

We purchased our 2022 Grand Design Reflection in January 2022 and were told it is good for full-time living since that is what we do. We have had issues with the slides, roof and other items list below: 3/11/2022 - Warranty Items: Driver side large slide won’t go in all the way and driver side front slide jumped a tooth. 6/9/2022 - Warranty Items: Bedroom slide (driver side front) mechanism needs to be completely rebuilt. Large slide (kitchen) has a bent bracket. 11/23/2022 - Warranty Items: Bedroom slide seized up (replaced slide system). Roof staples and screws poking through (resolved). 2/6/2023 - Non Warranty: Fridge shock cord snapped and fridge fell forward. Purchased new shock cord and installed. 8/9/2023 - Non Warranty: Fridge not working, bad board. Warranty passed and extended warranty said they would not pay due to the fridge fell forward in the past. Gerster paid to replace the fridge. Warranty Items: Spare tire coming loose after every travel. Shop replaced the wench. 6/6/2024 - Warranty Items: Slide on passenger side not sliding correctly. Room track is ground down causing gears to slip. Shop replaced the assembly. 7/6/2024 - Warranty Items: Fridge randomly stops working, needs replacement. Extended warranty covered all but $150 deductible. 6/6/2025 - Warranty Items: roof staples and screes poking through (roof replaced). Driver side large slide pin bent (replaced). Tech found cracks in the fiberglass above the slide at the rear. The cracks are on the inside in the same area (Submitted a claim to Grand Design. Waiting). 6/27/2025 - Pulled into campground and tried opening the window by the dining table. It is stuck. Had to push and hold it closed and then the release lever worked. Randomly throughout our travels, we stop at different places and notice pieces of trim/wood on the floors. Two kitchen drawers and one dresser drawer open during travel so had to install new drawer slide hardware. I'm having trouble attaching details.

Crack in side wall . This Crack was already fixed by the Grand Design once . A year later I looked at wall and Crack is back . This is one of many issues regarding this rig . Most of which I fixed myself . 1st issue the door was improperly installed . It would open going down the road . I fixed it by reinstalling door . 2nd issue main floor of rv has hump in floor , north south , using Lazer the hump was 1/2 " higher in the center of rv . This hump interfered with main slide coming in and out . Floor of slide was wearing away because all the weight of side was riding on center of slide . This issue was "fixed " at the factory . Now the main slide has has broken away from the floor on the left side . I fixed this issue .

Cargo Bay doors open while driving. The skirting screws along the wheel wells have become loose and started flapping while driving. refrigerator doors opened spilling contents while driving. The table lock failed and the table came loose while driving. water leaks in the undercarriage. front jacks and brackets are bent or broken. Have found sawdust on the counters and floor after driving.

We purchased the coach fall 2022. First major trip was in summer 2023. The main slide out failed (stopped working halfway out and would not extend or retract) the second night of camping. There was not a local repair facility available. A mobile repair person was able to get the slide out retracted. He informed us there was only one screw holding the main slide out frame in place. We wrapped a ratchet strap around the coach to hold the slide out in so we could at least continue our trip. A remote repairman at out next stop reported this is a common occurrence on this coach and it would need to be completely rebuilt. We noted that during transport there was sawdust on the cabinets and floors which we have been informed is evidence of excessive frame flexing. We took the coach back to the dealer from which we purchased the unit. The slide out had to be completely rebuilt (new rails, new slide blocks, new motors). We have little confidence that the slide out will not fail again. We noted that the rear tires were wearing at a rate of more than 4 times faster than the front tires. The excessive wear was accompanied with concern that we would blow a tire on the road and cause an accident and/or injury. A Lippert representative was consulted who advised that the front axle was defective and had to be replaced. Our extended warranty did not cover the cost of the axle. The next major trip was in summer 2024. The main slide out failed again. A repairman noted that the motors and rails needed to be replaced again and that the frame was at the limit of being within specs and may have contributed to the problem. During that repair the repairman noted cracking in the roof seams at the major junction at the front of the camper and around AC units and vents. Each of those areas had been resealed just 5 months earlier. We were informed that this was also evidence of excessive frame flexing. The repair facility diagnostician reported that the roof needed to be scraped and resealed.

Frame and structure issues Entrance door opens during transit Propane compartment opens during transit Large slide difficult to extent

While returning from a recent camping trip my wife while following the trailer home noticed the house structure was swaying and bouncing too much. She had thought the rig would fall apart. We arrived home and notice that the slide was out 2-4 inches, the cabin door had opened, an interior wall had separated from exterior wall and a side wall had flexed 2 or more inches out by another slide. There was bends and creases in the exterior metal side skirting that needed to be secured for travel. on approximately 11/04 we turned in the rig for repairs to Happy Daze RV. They Have since made us aware of frame cracks through out the trailer. We have not been notified of who or how the repairs will be handled.

The welds for the rear wall framing have broken loose and the rear wall is shifting side to side. I assume after time it could fully detach from the trailer and fall into the roadway. The trailer has not been inspected yet, but there are other cases documented on the internet. [XXX] [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

There is an issue with the structural integrity of the front upper deck where the walls are bolted to the frame. The only fasteners that I could find are loose and stripped out with no way of tightening them. There is also a lot of creaking and popping noises from the front upper deck area when hitching and unhitching the trailer from the tow vehicle. This is the same issue as with the Solotude and Momentum product series, also manufactured by Grad Design.

Both sidewalls on my 5th Wheel have broken frames at the top of the walls and the walls need replaced. The side doors and compartment doors come open going down the road. The large side window exploded going down the road from the frame twisting. The RV has to be sent back to the factory to be repaired and have the walls replaced

-Baggage compartment doors, when latched securely and locked with key, would open during travel down the highway at random. Luckily no cargo was lost (I take turns very slowly and noticed flapping baggage doors in my side view mirrors pretty quickly). This has happened on multiple occasions, and continued to happen after multiple dealership service visits that supposedly rectified the issue. This issue first appeared within 100 miles of purchasing this travel trailer brand new. -Yes, Adventure RV of Cheyenne, WY (now Blue Compass) verified the issue and eventually replaced under warranty the baggage door latches, and then after issue persisted and I complained, replaced the baggage doors entirely. -The issue persisted, contacted Grand Design corporate to open a complaint ticket. I requested permission to have trailer inspected and issue resolved at Windish RV in Longmont, CO as the Cheyenne dealership was incompetent and dishonest. Windish RV was fantastic, but Grand Design refused to authorize anything else for the baggage doors issue. Windish RV suggested I should upgrade the latches/locks to a high quality replacement, as the factory latches are mostly plastic junk, all the locks are keyed the same, and issues with them are almost guaranteed. On my own dime I replaced all of the baggage door latches with RV Lock (Utah, USA small business) replacement handles and locks (nearly $500 plus labor). This resolved the issue (around 5k mi since install). This was very expensive and time consuming but the safety and peace of mind is priceless. If items from the open baggage compartments fell out onto the roadway it could have caused massive property damage, injuries, and loss of life to my occupants and anybody else on the same road at the same time as me. -I can provide the warranty repair attempts documentation at a later date, as that paperwork is currently inside the trailer at a repair facility for other issues currently.

-Entry door of travel trailer opens during travel even with both deadbolt & handle locks in locked positions. -This could allow items inside travel trailer to be sucked out onto roadway. That could lead to property damage, injuries, & even death to myself, my passengers, & any other vehicle on the same roadway as me. Potentially making impact with road signs, other vehicles, bicyclists, or even pedestrians on side of roadway. This has also allowed diesel exhaust soot to be sucked inside the travel trailer, coating the ENTIRE interior. Created slip/fall hazard (I nearly fell) as it made the vinyl flooring incredibly slick. Harmful to health (covered the toilet seats, furniture, cookware, etc. I had to clean EVERY surface of the trailer interior to prevent harm to myself & my labradoodle (began to lick himself to remove soot picked up from interior surfaces). Multiple albuterol inhalations required during cleanup due to my asthma. -Multiple occurrences even after multiple dealership service visits. Issue first appeared within 100mi. of purchasing travel trailer brand new. -Adventure RV Cheyenne, WY (Blue Compass) verified issue & replaced under warranty entire entry door. -I contacted Grand Design to open a complaint ticket. I requested permission to have trailer inspected and issue resolved at Windish RV in Longmont, CO as the Cheyenne dealership was incompetent, dishonest, & failed to fix this. Windish RV was fantastic, but Grand Design refused to authorize further action for the issue. Windish RV suggested I should upgrade the door handle to a high quality replacement, as the factory handles are mostly plastic junk & same keys as every other trailer (not very secure). On my own dime I replaced the handle for $300+ labor with USA made RV Lock V4. -Appears door frame is separating from trailer wall, trailer currently at Windish RV for another repair attempt.

The large slide that has the fridge and dinette has a inadequate schwintek slide mechanism that fails and leaves the buyer to fix out of their own pocket. About all of the floor plan 28BH has this problem. Grand Design may attempt to fix it but it's a bandaid. I have had to pay out of pocket to get the VROOM system to replace the schwintek system along with everyone else that has it. The schwintek slide system is weak and problematic as it strips gears, looses timing and burns up motors. We have only used our camper for going on three years.