2022 Grand Design Momentum

I am submitting this complaint regarding a 2022 Grand Design Momentum 381, that is exhibiting numerous symptoms commonly associated with excessive frame flex, structural deformation, and potential frame failure. The symptoms observed include concerns affecting multiple structural systems of the RV, including the front pin box area, walls, slide-outs, floor structure, suspension attachment points, towing stability, and general structural integrity. These symptoms are not isolated cosmetic issues but instead appear to represent a pattern of progressive structural distress. Critical Structural Symptoms Observed Front Structure / Pin Box Area Excessive pin box movement Upper deck movement Front cap movement Structural noises during hitching and towing Stress cracking around structural components Structural Separation Wall separation Trim separation Fastener failures Screws backing out Loss of structural attachment points Interior Structural Indicators Cabinet separation from walls and ceilings Joint separation Wall movement Progressive structural movement over time Slide-Out Structural Concerns Slide misalignment Alignment changes Structural movement around slide openings Frame and Weld Concerns Cracked welds Structural deformation indicators Evidence of ongoing frame movement Towing and Highway Safety Concerns Changes in towing characteristics Increased trailer instability Hitch movement Concerns regarding safe highway operation According to the attached frame failure symptom checklist, several of these conditions are considered high-probability indicators of structural frame distress. Request for NHTSA Review Request for NHTSA Review Given the number and variety of structural symptoms present, I respectfully request that NHTSA evaluate whether this vehicle exhibits conditions consistent with excessive frame flex or structural failure and whether this complaint should be reviewed in connection with PE24-029 or other ongoing investigations involving Grand Design RV

On a recent camping trip across the country, about half way we noticed that the door was not latching correctly, then we noticed fine powdery sawdust and bigger chunks of saw dust. We started to notice squeaking in [XXX] When we got to [XXX], a loud crunching noise was developing, starting out, stopping and turning. in [XXX] we noticed a lag bolt backed out of the frame and pushed trim off the wall. as we drove back home the crunching sound, squeaking got louder, and the camper started chucking. when we pulled into the campground in [XXX], and stopped the camper moved and crunched. we then drove 565 miles to home. trim had fallen off the walls, the cabinets would not open and the pin box was not sitting on the entire fifth wheel hitch. I followed Grand Designs technical service bulletin to check frame flex. I found two cracked welds on frame gussets. i took measurements at all the points listed and they were all out of spec. the worst is the pin box movement. it went up 2" before the camper moved. in the video, you can see it moving independently from the nose of the camper. the distance from the pin box to nose decreased by 1 1/8" the frame is flexing and raising up into the camper. this explains why I was having difficulties getting the hitch to release, the king pin was binding in the jaws of the hitch because of the excessive pitch of the pin box. when jacking up the camper and raising it 1/2" off the floor on the passenger side, the landing gear on the driver side was still touching the floor. the camper crunched, popped and cracked as I was raising it, as I lowered it the noises were louder and lasted after the weight was off of the pin box. inside the camper the noise was louder than outside, the floors crack and pop when walked on in the bedroom and bathroom, and the cabinets rubbed the walls 3/4" the frame in the basement has visible signs of metal sliding as much as 1/2". the vehicle is not safe to tow. I cannot find anyone willing to look at it INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATIO

The contact owns a 2022 Grand Design Momentum RV. The contact stated that there was an excessive frame flex in the body of the RV. The contact stated that the walls were separating, and the doors were opening unintendedly while driving. The vehicle was taken to the local dealer, where it was diagnosed and the lag bolts were replaced. The vehicle was repaired, but the failure reoccurred. The manufacturer was contacted, but no assistance was provided. The failure mileage was unknown.

The contact owns a 2022 Grand Design Recreational Trailer. The contact stated that while the trailer was parked, an inspection of the trailer revealed that the front passenger-side door was inoperable and failed to properly open and close. The contact also noticed sawdust present in the bedroom area of the trailer. Additionally, the generator compartment was inoperable and failed to lock properly. The contact received a recall notification from the manufacturer related to the trailer. The trailer was taken to the dealer; however, the trailer was not diagnosed or repaired. The dealer informed the contact that the trailer needed to be inspected, and photographs of the failure were sent to a specialist for further evaluation. The contact later stated that the dealer advised that the inspection had been canceled after the photographs were submitted. The trailer was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 200.

Lag bolts that connect the frame to the wall are coming out/ or were never put in place. Wall is separating from the frame and can see to the outside from the inside. If we had not seen this these bolts could have come all the way out causing the wall the separate while driving. Unknown at this time if there is any frame damage. Grand Design 2022 Momentum 381m

The contact owns a 2026 GMC Sierra 3500 used to haul a 2022 Grand Design Momentum RV. The contact stated while driving approximately 70 MPH, the interior bedroom cabinets shifted and were rubbing against the wall. On another occasion while driving at an undisclosed speed, the contact pulled over and noticed that the 8-inch gap between the RV and the bed of the vehicle was no longer there and the RV was sitting on the bed of the vehicle. The contact stated that on another occasion, while parked, the contact became aware that the running lights were inoperable. The contact stated that on another occasion he observed that the bedroom baseboards were separating from the wall and there was a crack running along the side of the wall. The contact inspected the outside of the RV and noticed that the driver’s side wall was bulging and had a diagonal crack. The RV was towed to a dealer where it was diagnosed that there was frame damage due to poor design. The RV was not repaired. The manufacturer was notified of the failure. The failure mileage was unknown.

NHTSA – Complaint filed 7/24/25 ODI #11675985 1.Pin box movement within the upper deck, sagging geometry. 2.Entry door opens during travel despite safety bar being engaged. 3.Entry door is difficult to close and does not stay secured even when locked while stationary. 4.Passenger-side main slide partially opens during travel. 5.Passenger-side main slide is separating from the camper; frame is damaged, floor plywood is exposed and deteriorating. 6.Suspension wet bolts cracked on all six tires due to excessive wear from frame flex; all replaced. 7.Exterior garage door (near front cap) bows outward, opens during travel, and is difficult to secure even after Grand Design’s previous replacement. 8.Master bedroom dresser is detaching from the wall; sides are collapsing. 9.Washer/dryer doors no longer align; they remain open during travel due to changed dimensions. 10.Multiple interior wall cracks. 11.Master bedroom floor is sagging and produces loud noises underfoot. 12.Nails protruding through walls throughout the camper. 13.Ceiling and wall trim detaching throughout the unit. 14.Loft near the main slide is separating from the wall.

The contact owns a 2022 Grand Design Momentum RV. The contact stated while driving at an undisclosed speed, the camper was bouncing up and down. Due to the failure, the furniture detached from the wall. In addition, the bedroom floor fractured and pieces of the floor were separated. The manufacturer was made aware of the failure and the contact was advised to take the camper to a dealer in North Carolina, a six-hour drive away. The dealer determined that the failure was the result of nine lag bolts that were missing from the camper frame. The contact was informed that the failure was due to a manufacturer defect. The camper was repaired; however, the failure reoccurred. The contact stated that the pin box shifted downward, and the main slide on the passenger's side fractured and shifted down towards the ground and the furniture detached away from the wall. The main bedroom floor was fractured and sagging. The contact stated that while the RV was hitched and traveling, the main door unlatched and opened. Additionally, the garage door was bowed due to the failure of the frame. The manufacturer was made aware of the failure and a case was filed. The contact was advised to take the camper back to the dealer. The contact requested the manufacturer to buy the camper back, however the request was denied.

DUE TO EXTREME FRAME FLEX, THE WELDS IN THE FRONT OF MY COACH BROKE AWAY FROM THE METAL. MY UNDERSTANDING IS THAT THE ONLY THING HOLDING MY 44' TOY HAULER ON MY TRUCK WAS THE INTERIOR AND EXTERIOR SKIN OF THE COACH. I WAS HORRIFIED TO FIND THAT I WAS DRIVING MY COACH UNDER THESE DANGEROUS CONDITIONS CAUSING EXTREME RISK TO MY FAMILY AND THOSE ON THE ROAD. TO BE CLEAR, THIS FAILURE ONLY SHOWED ITSELF WITH ONLY MINOR SYMPTOMS TO AN UNTRAINED EYE. AFTER READING ALL THE COMMENTS ONLINE, I REALIZED THIS NEEDS TO BE ADDRESSED FOR EVERYONE CONCERNED