GRAND DESIGN Complaints

Made it 451 miles in our brand new Grand Design Solitude 380FL and noticed it looked crooked and smoke started coming from the drivers side while going 70 mph down I24 in TN. Pulled over and had a torn tire on both sides, axle was coming off due to missing a U bolt and the leaf spring had come apart. Fortunately we were paying attention and caught this as the 16,000 lb trailer would have flipped taking our vehicle and us with it. Mechanic came out, noticed locking bolts were not used on U bolts that were still in place, he was unable to fix it. Grand Design sent a mechanic down the next evening to put the axle back on so we could take it to the dealership. Took to dealership, they were supposed to make it "road worthy" so we could get it to GD Headquarters. This is a new to us vehicle so exactly how it "feels" when towing was also new to us. Noticed part way in the 482 miles to GD that the brakes associated with the previously problematic axle were not working, lots of brake dust on our truck. Once at GD they inspected and fixed multiple issues this caused after quite a bit of fighting with them as they did not want us to bring it to them. They also found we had a major leak in the regulator on our propane tank, mechanics exact words "you guys are lucky you didn't blow up". Our safety was put in extreme danger multiple times, as was anyone that might have been around us. As said previously, the mechanics at Grand Design did go over the vehicle after fighting with their service manager repeatedly. She wanted to me send pictures and they would deal with it that way. There were no warning lamps or messages. There was smoke 3 days after we purchased this from the dealer brand new.

We took possession of our new 2021 Grand Design 381M fifth-wheel travel trailer in April 2021. During 2021 and 2022, the trailer saw minimal road use. However, during our travels, we observed significant movement within the trailer, and on several occasions, the cargo bay doors opened while in transit. In August, we contacted Grand Design due to visible interior damage and abnormal movement. They arranged to pick up the trailer and transport it to their facility for inspection and repair. Grand Design confirmed that the trailer had suffered a frame failure. They reportedly completed the necessary repairs and returned the trailer to us. Unfortunately, not all issues were resolved. In May 2023, the trailer was returned to the facility for additional repairs. Afterward, it was returned to us once again. In August 2024, signs of frame failure reappeared. We contacted Grand Design, and a mobile technician was dispatched to inspect the trailer. The technician confirmed another instance of frame failure. Due to seasonal considerations, we arranged for the trailer to be transported back to Grand Design in March 2025. Repairs were made, and the trailer was returned later that month. We remain deeply concerned about the adequacy and durability of the repairs, and whether the trailer is truly roadworthy and safe. Despite multiple requests, Grand Design has not provided any photos of the frame damage or documentation of the repairs performed. This lack of transparency is especially troubling given the recurring nature of the issue and the broader concerns surrounding frame integrity across multiple Grand Design models. We are left with the impression that the structural integrity of our trailer—and potentially others—has been compromised. We believe this poses a serious safety risk for anyone traveling on U.S. roadways.

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

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 .

1. DETACHED REAR WALL The interior screws on the back wall tore a horizontal hole (approx 1/2 inch), and interior cabinetry joints are pulling apart. I looked outside to see if there were any signs that were indicative of rear wall separation. The Reflection 150 has an underbelly covering, so mostly the structure/frame is not readily viewable. However, investigating outside I found the black skirt wrinkled/buckled on the rear/drivers side. Upon googling, this is apparent indication of rear wall brackets broken/rear wall detached. 2. iFAME CRACKS ABOVE AXLES While investigating, I found severe iFrame cracks on both drivers side and passenger side. I contacted Grand Design who referred me to Lippert, who suggested we use a Lippert agent. 2 Florida local agents declined to get involved, so i returned to the dealer where i purchased the RV - 500 miles away in Georgia, after an email & phone consult. After 5 weeks, they said they would rather not do the job, and after 2 weeks prompting, Lippert agreed to schedule a 'courtesy inspection' - a month out. The dealer that inspected the RV stated that they thought the floor is subsiding & they think it is related to frame issues, but could not be sure without a more thorough inspection (but would need to remove under belly). 3. BROKEN LEAF SPRING In April 2023 we replaced all the leaf springs when we had one fail on the road.

Excessive frame flexing/failure in the upper deck of our 5th wheel.discovered damage is 1. Sawdust on furniture in the bedroom and by entry door from living area to the garage at intersection of wall and floor. 2. Furniture rub marks on wall in bedroom from upper cabinets with driver side having bowed out base or molding where it sits on window valance. 3. Separation of night stands from wall in bedroom on both sides and a curved wall in front.  4. Squeaky floor in bedroom on drivers side between bed and closet 5. Wrinkles and separation from steps and wall in the upper deck 6. Wrinkles around frame of hallway window in upper deck 7. Exterior of RV underneath the nose along where pin box is located there is separation with screws coming loose/out. The outside cap moldings loose and flapping in the breeze while going down the road 8. Lag bolts in the front section of 5th wheel that hold the wall to the frame some were missing, some coming loose, and all were undersized. These issues can contribute to further frame cracking and king pin failure that may result in significant property damage or even death, putting our family and others on our highways at risk. Grand Design sent a service repair technician (SRT) to inspect. During inspection a crack in the frame was found and told that welding would be needed. Appointment made at authorized repair facility and now the needed repair is being denied due to the pin box movement is at their minimum tolerance, yet the frame failure still exists causing a safety concern. Grand Design is aware of frame failure in several models and has yet to issue a recall of the structural defects caused by under sizing the frames and using the wrong lag bolts, and denying the repairs that are covered under their extended 5 year frame warranty.

I started noticing rub marks on the interior walls next to the night stands after the last few uses, and they appear to be getting worse after each use. I was made aware of the deck/frame flex issues the some GD fifth wheels are having and was referred to TSB 24-001. My RV is experiencing the exact concern described in the TSB. I opened a case number with GD, and took the RV to an authorized repair center. The repair center took measurements and confirmed my deck flex concern with GD and recommended a complete replacement/repair of the structural material and hardware. GD denied the claim! They only authorized replacement of the Lag Screws only, with larger lag screws per the TSB. In reviewing the TSB I don’t see how this fixes the problem! It only provides a temporary bandaid to the deck flex issue which will return after the next couple of uses. (The repair facility agrees that is a possibility). How does installing a larger fastener into an already compromised material provide a permanent repair? From what I’ve seen, the material it’s being screwed into is only 1” x 1”. Drilling a larger hole and installing a 1/2” dia. screw doesn't seem to leave much material left for structural integrity. Since GD has denied a complete and proper structural repair, I could only hope that this Deck Flex issue doesn't come back worse, resulting in an accident while traveling causing an injury or fatality. Being the original owner of this RV, I expected better customer support from Grand Design.

Slide out in kitchen creeps out during travel. Propane door opened during transit. Slide mechanism was replaced 14 months ago due to failure. Has now failed again. Frame had cracks repaired and additional supports added 5 months ago.

This is an ongoing problem. I have had multiple frame related issues with this 5th wheel RV. The bedroom closet wall separated causing items to fall into the opening, A crack developed that eventually reached 9 " in length in the sidewall by the bedroom slide. Most of the frame gussets supporting the rear and sides of the RV BENT and or the welds cracked. The floor sloped down at the edges due to improper support, Multiple times the propane doors opened while towing, Screws keep unscrewing from around the front of the RV. small cracks in the frame. The main bracket that holds the slide wall to the RV cracked and needed emergency welding while on the road, if it broke completely off the slide would come out while towing! After numerous attempts at getting Grand Design to fix this unit, I had to spend thousands of dollars to prove it was road worthy to tow it from Arizona to Indiana to their service center. They finally agreed to repair it. After 3 weeks we got it back with everything fixed or so we thought, less then 500 miles later the crack in the sidewall came back. After reaching out to Grand Design again they agreed to repair it again, 3 weeks later it was repair. Now the Wall the they repaired is moving, obviously something broke again. From the looks of it they didn't fix the problem just covered it up. The supports under the floor are bent and I had to put a 2x4 to support the floor, never fixed. We are full time in this RV and it gets towed all over the country. I have tried to reach out to Grand Design again for repairs but have been rebuffed in my attempt. This RV has been nothing but a disaster, having replaced a bent axle, numerous leaf springs and brakes. This RV was sold stating it was for Full Time living, we will attest that is not the case as they are not built well enough to sustain towing on the roadways of the U.S.A and Canada.