2021 GRAND DESIGN REFLECTION Complaints

We have signs of excessive frame flex in a Grand Design Reflection RV. We have allowed them 2x to inspect and they have botched both inspections. We keep being told there is no TSB or frame flex in reflections, which is not accurate as there are owners who have had cracked welds and major frame failure in reflections units. Grand Design needs to step up and support all customers not just momentum and solitudes because they are under investigation. I urge the NHTSA to expand their investigation to all Grand Design Models. Here is the list of signs of upper desk frame flex we have in our unit: 1. Lag bolts were backing out in bedroom (these have been replaced during the 2 botched inspections) 2. Graphics slightly bunching near trim 3. Screws backing out that hold on philon trim (we have been having to keep tightening them). 4. Philon trim had shifted significantly since it was just replaced (after 1 hr drive home from shop where my husband confirmed there were not gaps). 5. We also do have some noise hitching and unhitching like a creaking. We had 1st inspection in early 2024. It was botched. GD dealer did not follow procedures. We had 2nd late 2024. This too was botched. We have requested a GD SRT be sent to do a proper inspection and repair with us being able to observe the inspection. This request still unresolved going on a month. We have had our main door fixed multiple times because it does not close properly (could result in door opening while in motion). This could be due to frame flexing. We had a major issue on a trip in Nov 2023 in which both of our axles “bent” and we almost blew our 2 tires. This could have been catastrophic and we believe this may be due to under designed components or frame flexing. We also have frame cracks (at least one on each side of the ibeam main frame) that have been confirmed and are scheduled for repair 1/22/25. 1. Frame - yes 2. See above 3. See above 4. See above 5. Not specifically other than noted above

The Driver side rear outer wheel bearing seized and the wheel including drum came off the axle while driving about 30mph. The wheel rolled down the road but fortunately did not hit any other vehicles. The RV was towed to RV dealership. Dealership could not determine root cause of failure. The RV had approximately 10,000 miles on the trailer before incident. The bearings has been inspected and repacked prior to trip by certified RV tech. Before trip started RV was weighed at CAT certified truck scale and combined rear axle weight was 9200 lbs. Each axle is rated at 5200 lbs. Owner of RV contacted Dexter Axle, the manufacturer of the axle. As a second owner, warranty was no longer valid. Dexter representative did state that the replacement 5200lb axle outer bearing has been changed to a larger bearing. The representative stated that the reason for change was not due to reported failures but consolidation. The owner had both axles replaced with 6000lb axles and has driven 1250 miles since incident.

The metal frame supporting my RV body has started to crack. If a complete frame failure occurred while traveling on the highway it could/would cause a catastrophic loss of control and could/would result in major loss of life. This is a common problem with the Grand Design RV line and they have recently extended the warranty because of this issue. It is a well known and documented problem and a national recall should be put in effect. I would not have known about this possibly dangerous issue had I not read about it online and then inspected my RV;s frame exterior frame. I am also concerned that there may be additional frame cracks covered by body panels and I firmly believe Grand Design needs to inspect my RV for additional cracks that I am not able to do myself! I also should not have to be responsible for bearing the cost of repairing a defective frame that is happening to lots of RV owners and appears to be a manufacturing defect. This cost of repair should be the burden of the RV company.

I habe a 2021 Grand Design Reflection 303 RLS. The frame is cracked on both side just above the center spring shackles, I have also noticed frame flex between the pin box of the hitch and the rv body. I noticed the cracks when setting up the rv for the weekend and the frame flex driving down the road. I do not have any pictures of the cracks, but did attach a document to reference the frame crack and procedure to repair. The rv is at the dealership now being evaluated.

In 2021, we began noticing wall movement in the interior of the RV, fasteners, paneling and interior walls getting loose and moving. After more trips we noticed scratches in the flooring and wood chips laying on the interior floor when we would push the main slide out. We also began noticing the large slide didn’t seem to be closing tight to the outside wall on one end. After more inspection we noticed large roller marks appearing on the underside of the main slide. We scheduled our unit into the dealership for review. The Dealership identified bent frame rails, twisted spring hangers, frames cracks, bent outriggers on the frame supporting the outside walls. The dealership contacted the manufacturer and the manufacturer sent one of their service repair technicians (SRT) to my dealership for an inspection. Because we have heard and seen issues with broken springs, spring hangers and the risk they create from losing springs, wheels and axles etc. the dealership advised that using the RV was not an option until the manufacturer approved it for use. As a result, several trips were cancelled for potential safety reasons. The SRT and the dealership believed that the unit had to go back to the factory for inspection and proper repairs. The unit has gone back to the manufacturer and the frame manufacturer where major frame work has been completed. Now we have a reworked, modified, weak frame and based on the report I’ve seen from the frame manufacturer I’m concerned that they didn’t go far enough and only worked on adding support to 4 of the 6 spring hangers and the related frame areas. It appears that the work done to fix the frame has raised the overall height of the unit 2 -3 inches and added weight to the unit which affects the weight sticker on my RV. I have asked but still haven’t received an engineering specification that dictated the work done to the frame to help build confidence and make this a safe and reliable RV.

Cracks in the frame of RV above the spring-shackle hangers. Did have them repaired, but it should not have happined

one brake shoe pad came completely off the mount plate, so no effective braking on that wheel

The contact owns a 2021 Grand Design Reflection RV. The contact stated that the structural slide seized and was inoperable. The RV was taken to the dealer where it was diagnosed with a faulty camber. The mechanics and the manufacturer's technicians performed numerous repairs by welding the frame; however, the failure recurred. The RV was then taken to the manufacturer's factory where the technicians added structural steel to strengthen the frame and replaced the front and rear axles; however, after the repair, the front cap was leaking water and there was black mold inside of the RV. The manufacturer was made aware of the failure. The failure mileage was approximately 1,600.

While parked in an RV park I discovered that the right rear spring hanger on my fifth wheel RV had fractured and separated immediately adjacent to a weld line. I am unaware of any incident that can explain this damage, although I did hear a clunk while auto leveling the vehicle at our campsite. (Auto leveling is computer controlled and is a routine operation.) Inspection of the intact left rear spring hanger reveals what appears to be a small crack that may be the beginning of a similar problem on that side. An undetected failed spring hanger when traveling at highway speeds can obviously be a cause of severe property damage and death. Research of this problem in user groups and forums revealed that it is well known to vehicle owners. Anecdotes of broken hangers abound, as do user-invented fixes. Interestingly, Lippert (aka LCI, who is the manufacturer of the vehicle frame) reportedly has a repair for the problem that it has retrofitted to some vehicles and is apparently using in some newly manufactured vehicle frames. The fix is to add a 'V-brace' that is welded to the spring hangers and increases their strength. Example: https://gdrvowners.com/forum/operation/suspension-amp-brakes/52915-spring-hanger-advice There are no recalls for my trailer suspension that I can find, so despite apparent knowledge of the issue the manufacturers of both the frame and the vehicle have failed to warn me or others of it. I am now working with both Grand Design and Lippert to solve this problem on my vehicle. I will press for confirmation that the 'V-brace' is a viable repair that won't violate my warranty and will press to have it implemented on my fifth wheel RV.

Improper routing of 110v wiring on RV Gas/Electric Refrigerator circuit wiring leads to wire contacting the refrigerator "chimney" (boiler flue) which over time burns through the wire insulation cover and results in "live wire" to metal contact and can lead to FIRE! Grand Design RV is aware of this issue! One customer had a fire as a result of this poor installation practice and posted the info on Facebook, stating Grand Design, a Fire Inspector for the Insurance Company and an agent for Norcold Refrigerator determined the cause of the fire as improperly routed wiring. Grand Design has not alerted owners of this potential critical safety issue with a Safety Bulletin, VIN Recall or any other means to alert owners of the hazard. After reading it, we inspected our unit and found the same issue. Grand Design failed to authorize an Emergency Inspection and Repair for 3 business days (4.5days total) despite me notifying them of the fire in another unit. I also informed them that on Grand Design Owners Technical Forum, several other owners are finding the same issue. We hired (at our expense) a Mobile RV Service Technician to inspect and repair our wiring. He found the wire in question to be completely burnt through to the individual wires. It was a matter of time before we would have a fire as well. He made the necessary repairs on 15 June 2021 and we filed a Warranty Claim with Grand Design. We had no circuit breakers trip or any other indication that there was an electrical wiring issue. The refrigerator worked normally and was drawing the correct amperage and all outlets worked normally. Grand Design's poor routing and installation of the wires is creating a significant safety hazard and their failure to notify customers in any way of the potential hazard is very disturbing. Coupled with their lack of urgency in addressing the issue when I called in can possibly lead to unsuspecting owners having fires that could lead to serious injury and death.