2021 GRAND DESIGN SOLITUDE Structure Problems

The contact owns a 2021 Grand Design Solitude Trailer. The contact stated that while driving approximately 60-65 MPH, the cargo doors opened independently. Additionally, the contact stated that the built-in tables were detaching from the wall, and the wall panels were separating in the bunk room. The contact also noticed that the walls were separating from the floor. The contact related the failure to NHTSA Action Number: PE24029 (Structure). The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The manufacturer was not notified of the failure. The failure mileage was unknown.

Current Symptoms (post-repair): Excessive Frame Flex: - Pin Box Flex, including cracking sounds - Bulge in bottom corner of front driver side slide - Decal ripples - Screws snapping - Door alignment issues - Sawdust on interior furniture after moving - Pinch molding issues - Screws backing out Repairs were made on the unit in Feb 2025, however the above symptoms are still present (or have worsened) since the repair was completed.

Visible indicators began to appear both inside and outside of the RV within the past 12-18 months that were indicative of a structural problem. First, we noticed separation underneath the front cap where it is sealed with the bottom molding. Next, we noticed the wood paneling facia board behind the front bedroom closet, in the front nose cap, had almost completely separated from the closet shelving. Additionally, the adjacent closet, doubling as the Washer/Dryer closet, had wood paneling separating from framing. Most recently, we observed three separate nails/and or screws, protruding through the front, bedroom laminated flooring. With all of these indicators visibly present, we contacted Grand Design customer service on Friday, April 25, 2025 and reported these visible warnings indicators to Grand Design customer service and requested pre-authorization for a stress test to be conducted in at attempt to determine if our RV had frame flex. On May 7, 2025 we took our RV to General RV in Draper, Utah to have this stress test completed. This test was paid for by Grand Design. The test concluded that our RV did in fact have frame flex and required repairs. General RV filed a claim, on our behalf, with Grand Design for the frame repairs, but NOT the interior damages to the RV as noted above. Grand Design approved the frame repairs under the 5 year frame warranty. This work on the frame was concluded on Friday, May 30, 2025. To date, we have been diligently working with General RV, Draper, Utah to have Grand Design approve the claim to have the interior damages repaired that are a direct affect of the frame flex damages, however, to date Grand Design has denied to approve this portion of the claim extended under the 5 year frame warranty.

My fifth wheel has extreme frame flex which caused compartment doors to come open while traveling sometimes allowing things to fall out while traveling. Having a screw driver falling out and hitting another car was a major concern. Grand Design has the camper to address the frame flex. I believe the frame flex was the cause as sometimes the latches wouldn't engage.

Since we have purchased our RV we have had several issues with it. Since the first trip the entry door will not stay shut while in transit and continues through today We had requested the dealer check it out but the issue was not remedied. During the time we have owned the RV we have had to have the roof replaced due to poor workmanship at the factory. We had had the TSB for the rear compartment completed however the cargo doors are not aligned properly and one door on the driver side is starting to wear through the aluminum on the side. We have also had the rear cargo door pop open on more than one occasion. We have also had the TSB performed for the improper lag screws being installed at the factory. On one corner of the front of the frame which had cracked they used a 1/8th inch screw with a 1 inch washer instead of a 1/2 by 3 1/2 inch lag screw. The floor in the living room area is dropping up to 1/2 inch at the wall in the front and back of the slides. We have walls starting to separate in the coach as well as the stairs separating from the walls going into the kitchen and the bedroom. There is trim separating from the walls in the bedroom. While this is not the whole list of what is going on it is a good representation of the issues we are facing.

Issue Description: On multiple occasions during travel, cargo doors and the main entry door have opened while the vehicle is in motion. We have been fortunate to notice the doors flying open, allowing us to quickly stop before losing any cargo. Cargo Risk: These compartments carry cargo. When the door flies open, there is a significant risk of cargo flying out of the vehicle. This creates a hazard for oncoming motorists, either through airborne cargo or cargo on the roadway. Evidence of Problems: Missing sidewall screws in front storage. Loose sidewall screws. Bulging on the frame on both edges adjacent to the pin box. Poor alignment of cargo door and entry door. Kitchen slide is binding, preventing proper opening and closing Symptoms / concerns of excessive frame flex

Frame failure in front end of fifthwheel. Reported and rewarded at factory. Failure to install all lag bolts holding front of frame to structure. Four baggage doors damaged from movement.

We have extensive frame failure on the front cap of our RV. We are unsure of anything rear of the RV. We had broken welds, missing bolts, and flex while towing. It was inspected by the manufacturer and was outside of their frame flex limits and was deemed unsafe to drive until repaired. We have had it fixed and an ibeam installed as well as welds fixed and other beams installed on the side for support. Grand design has been involved all reports and did come for inspection at the service facility. Warning signs prior to failure: movement of interior furniture against wall, doors coming open enroute, doors not closing correctly, trim coming off enroute, screws coming loose, floor of front of camper creaking.

Bish’s RV in Boise has confirmed that our unit is experiencing frame flex again. Our RV is under warranty and we have been waiting for over a month to hear back from Grand Design. This began in January 2023, we took the unit to a service center for repairs, which took over a month. However, after towing just 45 miles, the issue reoccurred. We were then sent to McClain’s in Sanger, Texas, where SRT Chris found that lag bolts had been left out during manufacturing. He replaced the seal plates with thicker steel and made necessary adjustments. Now that this issue has happened a third time, I’m concerned that the breaking seal plates are a symptom of a larger structural problem. We've also had a cargo door open during transport, along with a broken leaf spring and suspension. At this point, I have little confidence that a proper repair is even possible.

Side front cargo compartments have opened during travel. Left and right side in two seperate incidents. Cargo fell on highway in one incident.

Trailer is not manufactured in compliance of FCR Title 49 393.70 a,b,(ii), California Code of Regulations Title 13 and Cal.Vehicle Code. Coupling devices and towing methods, as it is a known fact that 5th wheel hitches are breaking frames. Hitch will flex vertically 1 to 3 inches when towing. If towing truck has USDOT and/or California BIT numbers on side of truck the trailer is bound to Federal and State Motor Carrier Laws as trailer is part of combination. Hitch weight is overweight by 106 lbs empty, see attached weight sheets and product sheet. Grand Design main sales phone number confirmed Max Hitch Weight is correct on sales brochure. We cannot legally install generator or washer dryer in front compartments as trailer will be at least 500lbs overweight on hitch. During trips, front cargo door and rear cargo doors have come unlatched. When trailer was purchased, brakes were not operating properly, called dealer, the brakes are self adjusting and will get better. I knew better and fixed myself, Dexter reimbursed me for parts. Trailer will go to Grand Design Dealer for repairs to hitch and upper deck failure in February 2025.

We are having issues with the frame flex failing, screws popping out from around the slides and also around the wheel wells. Seams on the exterior are pulling apart, roof is pulling away in several spots. The slides are pulling in crooked, external compartment doors open while traveling down the highway. Sawdust is noted in multiple spots in the interior of camper. We had the springs fall apart ( they literally fell off onto the highway!) and caused the axle to shift forward while driving down the interstate. Our camper was going sideways down the highway and caused a flat tire and left us stranded on the side of the highway. Thankfully we didn’t not hit any other vehicles. There is also a burning smell in the camper, the generator turns on and off randomly by itself.

I noticed wall movement against installed cabinets in the front of the RV. Movement was indicated by the shaving of the wall material leaving "sawdust" all over the front RV bedroom area. Upon inspection half of the required lag bolts were installed and those installed were too small for the pre-drill holes. Frame inspection by a dealer indentified split side wall support rails on both sides of the RV. My inspection also found bent outriggers which has allowed both side of the RV floor to sag down on the outside of the camper.

Frame failure on the front of my 5th wheel. It was “fixed” once at Grand Design but now it’s back after less than 500 miles.

On multiple occasions during travel, We have had cargo doors and the main entry door open when going down the road. We have been fortunate that we have noticed the door flying open, to where we can quickly stop before losing any cargo. Because these are cargo doors, we carry cargo in these compartments. When the door flies open, there is a huge risk of cargo flying out of the vehicle and creating a hazard for oncoming motorists (flying through the air or upon the roadway). We have adjusted the latches on these doors to no avail. we get them to where they work and hold fine, then will start coming open again. We believe based on other evidence (missing sidewall lag bolts, loose sidewall lag bolts, bent sidewall lag bolts, popping sounds when raising or lowering unit, broken slide mechanisms, excessive sawdust on the inside of the vehicle, doors on internal cabinets unable to be opened due to interference, millwork trim falling off) that there is a frame failure or suspension issue with this vehicle causing excessive flex. These issues pose a life safety risk to any person traveling on a roadway.

Frame failure causing significant issues across entire RV. I first started noticing issues around July of 2022

Serious frame failure issues. Upper deck of trailer is separating from cross members to lower frame. Pin box has signs of excesive flexing, when hooking to truck, it sinks back into the frame well over 1.5”. Creaking noises coming from floor in front broom area as well as bathroom. Continues to get worse

I observed a small protrusion under the upper deck of our fifth wheel when we left Texas heading to Florida. When we arrived in Florida the protrusion was much worse. After I removed a plastic panel I discovered the frame was broken where the wall has been traveling up and down and broken the frame supporting the wall. If I didn’t notice this so soon it would cause the wall supports(lower frame members) to completely break and to possibly separate from the trailer while traveling down the road endangering everyone’s lives as well as my family. The manufacture refuses to investigate stating that’s their policy because we are second owners. It has not been looked at by dealer because we are unsure if it will make it to the dealer without breaking completely. It is available to be inspected but looking to have it repaired soon to continue our travels when deemed safe to travel.