2022 Grand Design Transcend

1. Complete Trailer brake system failure due to incorrect wire gauge used during assembly at Grand Design. 2. Frame failure at axle shackle weld on Lippert frame due to over-penetration. While towing the trailer there was a message on the tow vehicle information center "trailer Brakes disconnected". All trailer breaking was lost while going down the Siskiyous. At that time the trailer began to sway and was difficult to maintain control due to the loss of trailer brakes. During assembly Grand Design used 18-gauge wire to connect the 14-gauge wire from the brake magnets and axle tube to the wire running through the trailer underbelly up to the Vehicle plug. Lippert brake installation manuals for 4 brake systems state to use at least 14-gauge wiring. These manuals are readily available on the Lippert website. The photos we have provided clearly show 18 gauge was used and its insulation had melted exposing the center conductor. Repair documentation from the dealership to fix the brakes indicated that the right rear magnet was intermittently bad drawing high current which would draw all the braking system current to that one assembly. This maximum current to one set of wiring caused the smaller 18-gauge wire to melt off its insulation which resulted in a hard short that prevented all braking at a very inopportune time. Had 14 gauge been used we would not have lost all braking to the trailer. During the brake wire repair at the dealership the frame around the RR axle shackle failed when the trailer was jacked up. It appears that the shackle attachment weld over-penetrated the frame ultimately causing a weak joint and lead to the frame failure. The frame failing around the shackle weld happening at the dealership instead of on the road is beyond lucky and avoided another very unsafe incident on the road. These two items happening at the same time almost resulted in a multi vehicle crash on I-5 southbound.

NHTSA ID

11648334

Incident

Jul 3, 2023

We were driving home from the Denver area on Sunday, [XXX] at [XXX]. After about 15 minutes of driving, another driver pulled alongside and told me a tire was missing. I pulled over. One of the trailer tires (driver side, furthest back) was gone. It was nowhere to be seen. The bolts holding lugs nuts were sheared off and the trailer fender was broken. The tire must have damaged the fender when it came off. -The tire assembly malfunctioned - this is only over a year old. -As for safety, the loose tire could have caused major damage. I had no way of knowing it came off since we have dual axles. -I have not taken this into the dealer yet. I called roadside assistance, but it was closed because of the day being a Sunday. I did call an emergency service to repair the wheel, axle, brakes, etc. -I am working with our insurance company and the dealer - no luck so far. They have not inspected it yet. There were no warnings - thank goodness someone told me it was missing. Thanks for consideration of our dilemma. [XXX] - INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11545925

Incident

Sep 10, 2023

Welds on the steel wheels are breaking. I've broken two separate wheels, one just backing into a site, and the other turning sharp at a gas station to get to a pump. The wheels are 2-piece, with the inner ring that welds to the outer hoop. The welds appear to be very thin and so just the pressure of a sharp turn is over-torqueing the tiny welds to the point of breaking. Thankfully this didn't happen at speed because it would have been a major accident. I can't trust any of the other wheels at this point and am forced to replace them all with aluminum alloy wheels.

NHTSA ID

11525367

Incident

Jun 2, 2023

LED indicator lights on the kitchen range knobs over heated and caught on fire. I was filling the pantry in preperation for an upcoming trip. When I turned on the pantry light to the motion sensing position there was a slight momentary buzzing sound. I turned the switch off but then noticed that the LED light on the range knob was smoldering next to me. The LED then caught on fire and I extingushed it with a kitchen rag. I disconnected the trailer from the household power connection and turned off the battery disconnect switch. A few hours later when my spouse arrived home I connected the shore power and the battery disconnect while she observed the unit. We observed that the lights on the other range knobs were illuminated even though the switch was in the off position. The pantry light was on but very dim. Within a minute or two a second LED ring on a different knob smoldered and popped. I immediately disconnected all power and than contacted the manufacturers customer service department when they opened the following day. They are supposed to be sending a replacement range to a local service shop for replacement. We are still waiting for the new range to arrive. The manufacturer has stated that they want the defective range returned to them for inspection. We have been unable to turn on any power to the trailer due to fear of another fire.

NHTSA ID

11463561

Incident

Apr 27, 2022

Attic Vents and solar ports on affected units may prematurely crack allowing for water infiltration. TSB 23-003. Issued December 29th, 2023. PDF attached .

A crack may occur in the existing skylight. As a result, there is a potential for water to intrude.