2023 Grand Design Solitude Problems

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.

Frame Flex & Water Intrusion - We first noticed movement back in August 2024. It seemed like the tongue was going to come through our back truck window where I sit to work with our 3 cats. The inside of the Solitude is a mess too with lights coming down from ceiling, doors are all scratch from rubbing while be transported, trim coming off, wall paper being torn apart, had lag bolts coming up through the floor, leakage in master bedroom, floor warping and more. We took it in to have it fixed in November 2024 to only get her back in late march of 2025. They had to weld and reinforce frame but would not admit to frame flex or provide me with an updated weight placard so it's like they don't want evidence on it. They had to replace the whole floor which meant they had to take off slides to get everything out and now she is back up there with severe water intrusions from slides and other things again. Moisture reader is reading in places between 30 to 48% but Grand Design is denying any water intrusion even thought they took slides out. They only respond after an email is sent. This is unacceptable and hope that one day we can get these RV manufacturers to follow same rules as a vehicle. Why are they all in IN - they have the most laxed laws governing recreational vehicles. Our lives are in danger while driving these RV's on US highways which means we are putting others in danger too. Why aren't they held to a higher standard...where is the safety in all of this. I have pictures all everything if needed for documentation. Thank you for your time.

The contact owns a 2023 Grand Design Solitude RV. The contact stated that while hauling the RV and depressing the brake pedal to stop, the RV pushed up against the rear of the pickup truck. The vehicle was taken to the local dealer, who discovered that the RV brake shoes had crumbled and failed. The contact was advised that the brake shoes and braking system needed to be replaced. The vehicle was later taken to the local engineering firm and the braking system was replaced. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 9,300.

All brakes were replaced after the first failure. Pulled 3445 miles. RR brake fell apart. Causing loss of braking from that wheel.

Frame Flex & Water Intrusion - We first noticed movement back in August 2024. It seemed like the tongue was going to come through our back truck window where I sit to work with our 3 cats. The inside of the Solitude is a mess too with lights coming down from ceiling, doors are all scratch from rubbing while be transported, trim coming off, wall paper being torn apart, had lag bolts coming up through the floor, leakage in master bedroom, floor warping and more. We took it in to have it fixed in November 2024 to only get her back in late march of 2025. They had to weld and reinforce frame but would not admit to frame flex or provide me with an updated weight placard so it's like they don't want evidence on it. They had to replace the whole floor which meant they had to take off slides to get everything out and now she is back up there with severe water intrusions from slides and other things again. Moisture reader is reading in places between 30 to 48% but Grand Design is denying any water intrusion even thought they took slides out. They only respond after an email is sent. This is unacceptable and hope that one day we can get these RV manufacturers to follow same rules as a vehicle. Why are they all in IN - they have the most laxed laws governing recreational vehicles. Our lives are in danger while driving these RV's on US highways which means we are putting others in danger too. Why aren't they held to a higher standard...where is the safety in all of this. I have pictures all everything if needed for documentation. Thank you for your time.

After my refrigerator stopped working, I pulled the refrigerator out to investigate and check fuses (a common issue) I observed the wiring connected very poorly, and was melted together. additionally, there was a burn mark 2 inches or more in diameter on the wall where these wires were touching. so there was a fire due to this wiring

My fifthwheel was installed with improper lag bolts, causing frame flex issues. I lost my roof going down the highway last year, pass-through storage compartment doors coming open during transit. Along with that, interior damage became apparent early on after the purchase of the RV, indicating a much greater problem than anticipated. Grand Design sent out an SRT to repair my unit; however, they failed to pull the pylon down off the front of the unit to inspect the frame welds. I may have an impending disaster going down the roadway in the future. All but one lag bolt was being held in under tension. The unit could have become detached from the tow vehicle, and the safety braking mechanism likely wouldn't have engaged. If my roof came completely off, or items would have fallen out of the pass-through compartments, this could have easily caused a major accident leading to fatalities on the highway.

We have excessive Frame Flex. Cargo doors and entry doors open on the road spilling storage contents on road. Axle Equalizer welds breaking. Doors Binding. Vehicle is overweight from factory, over specified weight placard on sticker. This is an on-going problem with Grand Design's larger 5th wheel trailers. They are unsafe on the roads.

This is a 5th wheel trailer by Grand Design ("GD"). We had significant frame movement due to improper construction and broken welds, resulting in: 1) Screws shearing off at the top of the nose cap, causing the roof to bubble and tear during transit. Roof and screws were replaced under warranty. 2) Entry door was misaligned and required adjustment to close properly (likely due to shifting of frame/body). Strike plate and lock adjusted. 3) Side door to propane tank compartment popped open during transit on the interstate. 4) Rubber strip covering siding/body screws under nose cap flew off during transit on the interstate. Rubber strip replaced. 5) Screws shearing off near hitch, causing siding under nose cap to sag. We were unable to reattach it ourselves with screws as recommended by GD because the frame no longer aligned properly. Front end taken apart and rebuilt, additional metal added by GD under warranty (refused to provide written details or to update weight). 6) Broken weld under front closets in front of nose cap (front bedroom model). GD initially denied welds were broken. Front end taken apart and rebuilt, additional metal added (refused to provide written details or to update weight) by GD under warranty. 7) Frame movement caused rear frame wall to detach and screws to pop out in interior (causing recliners to detach and move during transit). "Dimples" appeared on exterior lower siding ~4" up from rear on both sides. Unclear on specific damage, because GD will not fully explain in writing. GD added one ~4" piece of metal between the siding and rear wall framing on each side (picture attached) and replaced screws, under warranty. 8) Extreme wear on leaf springs, axels, and tires, caused by excessive movement due to broken/poorly engineered frame, requiring replacement. GD replaced parts, partially under warranty. GD stated the unit was not road worthy, but told us to haul it to them. They refused to send pictures of damage or repair other than the one.

-Movement at the kingpin when lowered on tow vehicle along with door side wall and upper cap separations, major concern especially while traveling for us and other traffic -bedroom slide not coming all the way in remaining several inches out from where it’s suppose to this is the most recent issues added to our growing list) this is a major concern for us and other traffic while traveling -both exterior main doors and 2 cargo doors do not shut properly and pop open major concern while traveling (shifting door frames) -grease cap on same wheel has come off 3 times the first before we pulled out of the dealership and the 2nd within a couple hours after leaving the dealership also a big concern being part of the traveling part of this vehicle -water leaks in the upper deck, we don’t know where it’s coming from and found water dripping out from back side of kingpin and other places in the camper

The contact owns a 2023 Grand Design 5th Wheel. The contact stated that the propane gas pigtail was on the floor and created an electrical spark and popping noise that traveled up to other cords. The contact stated that the pigtail cord was improperly fitted and should not have been on the floor. The vehicle was not diagnosed or repaired. The manufacturer was not notified. The failure mileage was unavailable.