2023 Grand Design Momentum

In 2023 we purchased this RV. Recently, we discovered that the cargo carrying capacity is incorrect by about 900 pounds, subject to Recall 23V-428. Grand Design knew of this defect before the rig was sold; however, they didn’t remove the vehicle from the dealers lot, nor were we ever contacted by Grand Design. Grand Design knew of the issue in June 2023, and we purchased our rig in July 2023. We also have had the rig in for repairs for broken leaf spring supports and now they’ve done some welding on our frame because of frame flex issues.

Overview: This complaint is being submitted in response to alarming and persistent structural failures experienced in our 2023 Grand Design Momentum fifth wheel RV, purchased new in January 2023 from Lazydays RV in Tampa, FL. Despite receiving a factory service bulletin (TSB) and subsequent repairs under warranty, our unit has continued to exhibit excessive frame flex, wall and floor deformation, compromised slide operations, and related structural issues. The failures not only impact the unit’s functionality and safety but raise concerns about a broader systemic issue with the frame design and manufacturing integrity of Grand Design RVs. Our documented repair history and recurring defects suggest these problems stem from substandard frame construction and flex-related design flaws, rather than isolated workmanship errors. Final Remarks: We are not the only owners reporting these failures. Online forums and recent class action filings against Grand Design point to a concerning trend of recurring frame failures that the company appears unwilling or unable to resolve comprehensively. As consumers, we have exhausted all reasonable efforts to seek a resolution through the manufacturer and authorized third-party repair channels. It is our belief that these ongoing frame flex problems represent a safety hazard and require urgent federal oversight and regulatory action to ensure no further units are sold with such defects. We welcome a physical inspection of our unit by NHTSA representatives in the Richmond, Virginia area at your earliest convenience

This RV has experienced ongoing water intrusion due to faulty manufacturer-installed plumbing fittings and hoses, which allowed leaks into the interior. Moisture has reached electrical wiring, creating a serious fire hazard and contributing to unsafe living conditions. Essential components—including the furnace, refrigerator, and water heater—have proven unreliable or unusable throughout the ownership period. Mold growth has appeared due to the persistent damp environment. This has caused health issues, including respiratory difficulties, headaches, brain fog, and fatigue, with heightened risk due to a pre-existing asthma condition. Structural issues include misaligned exterior doors that fail to seal properly and loud creaking/popping noises during hitching, suggesting possible frame or chassis integrity problems. Equipment failures include a non-functional center awning, persistent sewer odor (suggesting a failed ventilation system), and malfunctioning A/C and heating units. Despite multiple inspections and documented findings from Grand Design–approved technicians, the manufacturer has offered only limited, pre-approved repairs that fail to address root causes. These problems severely impact the safety and habitability of the RV, which is used as a full-time residence. The manufacturer has declined a full inspection, replacement, or buyback. No warning lamps appeared, but symptoms began shortly after purchase and have worsened. The RV remains available for inspection. We request a formal investigation into possible safety standard violations.

The upper deck portion of the 5th wheel frame has been moving independently of the walls which is commonly referred to as "frame flex" or "frame failure", as evidenced by the following: a gap between the wall and floor in the bedroom above the upper deck, pin box receding into the trailer, loose, bent, and missing lag bolts which connect the upper deck to the frame, irregular slide operation in the bedroom above the upper deck, man doors in the trailer being out of square, cargo doors opening during travel, separation of the seam between the filon and "nose", squeaky flooring in the bedroom above the upper deck. The manufacturer has offered to transport the trailer to their manufacturing facility and perform what they are calling a "super" inspection if we agree to sign a release and non-disclosure agreement. The structural components of the trailer are covered by a 5 year warranty which should not require a release and NDA. The trailer is not safe and would be irresponsible to use in its current condition. The "super inspection" repair scope is vague, and the required legal agreement should not be required because the trailer is within the warranty period. The trailer spent almost 10 months at an authorized repair facility. The work done at the repair facility did not resolve or fully and correctly address the frame related issues. The repair facility has in its possession approx 400 pictures of the work performed on our trailer which they will not release to us. The work orders associated with the work done during the 10 months that the trailer was in the repair facility are vague and do not detail what was or was not done.

Purchased new June 2023 in Tuscon AZ. No issues until underbelly filled with water and had to be serviced in Albuquerque NM. Issue was not resolved with water pump replacement. Towed to Homerville OH not knowing water leak still exists and where frame flex was discovered. Man doors, propane tank doors, and basement doors randomly open while in tow and stationery. The seal for nose cone and felon broken and screws missing that secure nose to the chasse. May 2024, Grand Design picked up and towed the 5th wheel back to factory for frame flex repairs. A gusset "kit" was added, welded to existing frame. Door locks were adjusted, front man door replaced, one basement door replaced as it was water damaged, and is again. There were missing/never installed lag bolts for upper deck side walls. It is documented the lag bolts were replaced with larger ones and missing ones were added. Rear man door adjusted however still does not close from inside. There are huge gaps along door frames you can see daylight through. On Oct. 5, 2024, we towed the 5th wheel 10 miles to a winter location. When lowering and hitching up there was a very loud metal snapping, explosive sound came from the frame when the weight was put back onto the suspension. It was so very loud it made my heart skip a beat. It was like a cannon ball struck the metal frame. Definitely metal popping and snapping. As of today, Nov 21, 2024, the man door in garage is inoperable, the floors creek from nose to interior door to garage. The floors seem bowed. The front man door randomly opens when people or the dog walk past it on the inside. The basement doors randomly open and are water damaged. The slide in bedroom {holds the bed} is tilted and falling out of the wall. Air leaks all around the slide as if the frame is twisted. Grand Design states an SRT can be here in a couple of months. We are parked on an oversized level concrete pad. I feel the mixed metal the frame is made of didn't hold the welds. Not safe to tow.

The dealership has declared frame failure and failure of the pin box flexing up to 3-4 inches just picking it up with a forklift. Lag bolts are missing and/or backed out. Dealer has deemed it not safe for use. They will not move it out of their bay. Fist signs were wall separation throughout the RV. Doors not closing because door opening was out of square. Floor squeaking in multiple location. Center Island moves and squeaking. Abnormal wear on middle axle tires. Unusual pop from passenger level leg that shakes the rig. Excessive creaking underway.

We have a brand new 2023 Grand Design Momentum 5th wheel. Had her for 9 months. Taken only 2 trips thus far. I have a structural stress fractures on the corner of my closet slide (approx 4”), caulking around the front cap has been pulled away, both sides of our bedroom upper cabinets have about 3” cracks on the bottom along the wall from frame flex / failure. It’s difficult to close our main door. Often times it requires us to slam once or twice to get the door to close. All this is due to frame flex. I have spoken to Grand Design and they are sending a mobile SRT tech to my trailer to inspect and provide immediate repairs and deem the trailer safe to travel so I can take trailer to an authorized Grand Design dealer in New Orleans to fix our trailer.