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

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.

There are several things starting off with frame flexing issue causing numerous of parts to fail and move out of place. The manufacturer did a repair of this and my confidence in it being repaired correctly is very low. I do not feel safe towing this RV anywhere. Second, the broken leaf spring on the front axle. This could have caused the vehicle to lose control and cause a serious accident. It has been repaired. We have had the entry doors come open on us during towing. Nothing was lost from this. Lastly, the master bedroom slide has come out about 3 inches during travel. They repaired the inside bottom brace at the service center.

Multiple systems failed on this unit. Trailer Brake failure—The rear trailer brake wires were discovered to be severed inside the wheel drum from the factory. For the first year of use they were inoperable. This was suspected and confirmed with a thermal camera. The tow vehicle also alarmed “Check trailer brakes” while driving. A dealer inspected them and found the wires severed. This was repaired. Suspension failure—the rear driver side leaf spring broke on a paved highway 9 months after purchase. Pulled over immediately to inspect the issue and repair it. On 2 other separate occasions, we found broken wet bolts (after the unit was sitting in one place, unmoved for weeks). Also a cracked equalizer was replaced under warranty within the first year. The front passenger side leafspring also broke on an empty unit. Frame Failure & opening baggage compartment doors, slide out backing out in transit—symptoms of excessive upperdeck flex and frame failure began immediately upon purchase. Baggage compartment doors frequently open in transit. This has been a significant safety risk to the operator as well as other drivers. On more than one occasion the doors open in dense traffic in the middle of a city with nowhere to safely pull over. None of the contents of the compartment has fallen out to our knowledge, but could very easily fall out since none of the doors can be adequately secured. One door was replaced, but the issue not resolved. Upon further inspection, there were severely broken welds in the frame of the unit. The unit has sustained over 22 hours of welding on it to repair and reinforce the damaged frame. However, this has been repaired a total of 3 separate times. There is no guarantee that the repairs will hold moving forward. Also a result of the broken frame, the slide out began backing out in transport. Before leaving, the slide out was fully retracted and measured. Upon arrival the slide would be backed out 0.5-1” from the pre-departure measuremen

This unit is suffering from frame failure. Cargo doors have started opening on the freeway, cabinets are rubbing the wallpaper from frame flex, the forward floor has started squeaking, the forward lower exterior trim panel on the drivers' side is buckling, the forward walls have started creaking and popping when hitching up/unhitching and the pin-box "sinks" more than it ever did in the past when hitching up. I am very worried since these are all symptoms of frame failure. I've taken the unit to an authorized Grand Design repair center and so far, am not getting any support from Grand Design to actually fix the frame, the root cause for all of these symptoms. I'm worried if I accept the trailer and continue to use it, the problem will progress and we could end up with a complete failure while on the freeway.

The RV has significant frame failure that Grand Design (the manufacturer) is ignoring. I noticed my floors warping and a cabinet crack. There was also some cracking of the fiberglass. I asked the dealership to check it out. The found that the frame is warped, multiple lagbolts are missing and several welds have popped. The RV is unsafe and not road worthy. Grand Design is aware of this issue and has yet to issue a recall or notify owners of the significant structural defect they caused by undersizing the frame and using the wrong lagbolts.

A spring snapped in two near the mounting point to the frame. Rv was not overloaded. Grand design authorized replacement of all springs which is now complete. Others have had similar failures. Im guessing the metal used was too brittle. The busted spring can cause the rv to pull sideways a bit making safe controlling on the highway a possible hazard to everyone on the highway. An accident could occur endangering everyone around the rv with failed suspension. I managed to catch the failure before any injuries occured.

Upper deck failure ( side pod door opens when in transit, front of trailer at king pin mounting flexing when in transit, king pin mounting hits truck bed rails when turning, bedroom floor buckling, bed rollers leave indentations in bedroom floor closet door not plumb and will not lock when disconnected from truck, front wall height changes when connected to truck, trim and panels coming loose in transit. ). Wall to frame mounting has loose, missing and wrong size lag bolts. Inspection is available upon request. Door popping open in transit is a safety hazard for myself and everyone on the road. The vehicle has been to two different dealerships and the representatives at both mentioned frame issues as part of the problem. The first issues were noted at 2,000 miles on 9-19-2021