GRAND DESIGN Complaints

2023 RV unit experienced front cap cracking through complete cap. Grand Design stated it was a paint issue and would not warranty the damage. 2025 RV unit experienced exact same front cap cracking throughout the cap, side corners of cap and front side seam separation of RV. Interior seam and trim separation greater than reasonable and customary for an RV of this age and quality build. Repair shops, experts, RV dealers have stated these are certain symptoms of frame flex and pin box inadequacy. The potential exists for further frame damage and catastrophic failure, especially while in motion. The damage continues to broaden and manifest to greater degrees as time progresses, from front cap to now seam separation and interior wall/trim separation.

Weak bedroom floor. Screws backing out of bedroom floor and poking through flooring. Front nose cap separating from body. Broken screws on front nose cap. Pin box flex. Buckled wall in bunk slide out room. Main living space floor is bowing down where it meets the walls causing main door mis-alignment and the stairs to cause marks on the flooring etc.

The contact owns a 2025 Grand Design Solitude. The contact stated that the rear wall between the rear bedroom and bathroom had excessive frame flex after the RV was moved. The RV was taken to the dealer, who determined that the rear door was off track and needed to be adjusted, resulting in the wall bowing out. The RV was not repaired. The contact related the failure to NHTSA Action Number: PE24029 (Structure). The manufacturer was made aware of the failure. The failure mileage was unknown.

My Grand Design Momentum fifth wheel trailer is experiencing frame flex and structural integrity failure. The unit has developed spider cracking in the exterior fiberglass, interior wall separation, and plumbing issues believed to be caused by frame flex. The dealership has acknowledged structural concerns and installed lag bolts, but the underlying structural defect remains. Grand Design has denied that the frame flex caused the structural damage. This creates a serious safety risk while towing, including potential structural failure. I believe this is a manufacturing defect affecting the structural frame integrity.

October, 2025: At around 1800 miles on the trailer we inspected one axle set (RR)of wheel bearings and brake backing plate/shoe assemblies. This was prior to a 1400 mile trip with the trailer. The trailing shoe was found to be cracked and had material coming off in chunks. Upon contacting and reporting this to the manufacturer they sent a replacement backing plate assembly, drum and wheel bearings. The planned trip was made with the old parts. The braking on the trailer wasn't the best but they did not fail. Skip ahead to 02-22-2026 and we took the brakes apart on the one we'd reported and noticed immediately that the friction material that had begun to come apart had done so even more. We then sent another message to manufacturer regarding this, them took the remaining 5 wheels and brake drums off the trailer. Several had either cracked or missing friction material. One assemble, LF, had been greased excessively and had grease in the brake actuation coil, shoes and drum. I again sent a message with pictures to the manufacturer. They got back to me pretty quickly and parts to replace all of the brake assemblies are being shipped. Our worry is that many more units have this same faulty brake friction material.

• Cracks in the Pin Box: A reputable RV dealer/shop has identified significant cracks in the pin box, indicating a serious structural compromise. • Slide-out failures: The GIBs on the slide-outs have broken, causing them to extend while the RV is in transport on highways. • Cargo door malfunctions: Cargo doors are repeatedly popping open during highway travel. • Main entry door instability: The front door and screen are not operating correctly, preventing proper closure and causing the door to open unexpectedly during transport. • Structural fastener failure: Screws and bolts are detaching from the unit during transport. • Front cap detachment: The front cap is popping open at the fifth-wheel hitch area and exhibiting significant sway during transport. These issues collectively indicate a severe underlying problem with the structural integrity and frame of the 2022 Grand Design Solitude, creating hazardous conditions for both the occupants and other road users. I urge NHTSA to investigate these defects thoroughly to prevent potential accidents and ensure consumer safety.

The contact owns a 2023 Grand Design Momentum. The contact stated that while driving at an undisclosed speed, the entry side doors unexpectedly opened. Additionally, the slides of the trailer occasionally unexpectedly extend without operator input. The contact stated that the front frame of the RV was cracked. The RV was taken to the dealer, where it was diagnosed with structural failure of the front frame. The contact was not informed whether the frame could be repaired or needed to be replaced. The RV was not repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 5,000.

While performing a factory recall on the RV, the mobile RV tech discovered underlying issues. He suggested that we get an in-depth evaluation. I contacted and dropped the RV at the shop for diagnosis. The shop discovered extensive frame damage (weld break) at the main beam connecting the pin box and also total frame break and separation on the upper deck floor support. There is substantial floor sagging above the outriggers extending from the living area through the back of the RV. The whole rear of the RV is sagging, causing wall cracking and slideout damage. The shop also measured a considerable deflection (pin box to front bottom frame) while performing the manufacturer's instructions for the measurements. The manufacturer has denied our claim and we are tasked with getting home to permanently park the RV. The manufacturer communicated with the shop regarding their finds and the denial, but has not contacted me in any way. All recalls/TSBs have been performed. The rear TSB has not fixed the rear frame sagging and the front TSB was not 100% completed by a dealer, in that several lag bolts were not replaced and none of them had adhesive applied. We have been fortunate that we have had no doors open while traveling. I composed a list of the items we found and submitted it with photos to the manufacturer. They said that the RV qualified for the "Customer Satisfaction Campaign" and that it should take ~1hr for a visual inspection. They only paid 0.10 hrs.

I was informed to reference this code PE24029. 2021 5th Wheel - Grand Design Solitude 310GK. Frame cracks and separation. June 2025, contact made with Grand Design and they approved for us to obtain a welder. We did. It did not correct the issue and we contacted Grand Design again. Our Unit has been in the repair shop since December10, 2025. Back and forth emails with Grand Design. Sides need to be taken off to get to frame issues and make a repair. Would love for representative from NHTSA to come and look at our unit. The lower portion has been dropped, and you will be able to view. It's currently, in Santa Fe Springs, CA.

This report details a suspected major structural frame failure on my 2023 Grand Design Solitude 391DL. The issues, which are progressive and worsening, indicate a severe loss of structural integrity in the front gooseneck and upper deck area of the fifth wheel. Key observations and symptoms include: Interior Wall Deformation: Interior wall panels in the front bedroom are visibly buckling and warping under stress. Separation of Wall Panels: The rear wall panel inside the main bedroom closet has developed a significant gap and is separating, believed to be a direct result of excessive frame flex. Misalignment of Door Frames: The door frame for the front closet housing the washer and dryer has spread apart to the point where the door can no longer latch or close properly. This demonstrates a clear deformation of the coach's superstructure. Audible Structural Noise: The floor in the front bedroom section produces constant, loud creaking and groaning sounds when walking on it, consistent with a compromised frame and subfloor structure. Safety Concerns: The progressive nature of these failures raises significant safety concerns regarding the vehicle's roadworthiness. The loss of structural integrity in the gooseneck area could lead to a catastrophic failure while the vehicle is in motion, posing a severe risk of detachment, loss of control for the tow vehicle, and danger to other motorists. The integrity of critical components like the roof, slide-outs, and heavy appliances is also compromised. This issue appears to be consistent with a pattern of similar frame-related failures reported by other Grand Design owners, which are the subject of an ongoing class-action lawsuit. I urge the NHTSA to investigate this critical safety defect before it results in a major highway incident.