2021 Grand Design Solitude

*I believe the frame to my Grand Design RV is broken/failing again and is available for inspection. *If the frame fails and breaks it will come detached from the tow vehicle possibly injuring or worse killing people. *The problem is visible to see as there is at least one broken weld and lag bolts/screws backing out that no longer hold the frame to the wall structure. *The vehicle was previously inspected by an insurance agent, dealership, and multiple Grand Design SRTs-mobile technicians when it failed before previous repairs. *There was sealant that was failing again so when I started to remove it to replaced, it I noticed some broken screw heads so I dug farther into it and found the broken weld and lag bolts loose/stripped. This was noticed during a routine sealant inspection.

Beginning in 2024 our RV exhibited consistent structural movement & frame flex including: upper deck flex, front cap cracking, cracked moldings, sidewall movement, filon transition movement, screws pushing upward into floors, slides coming out during travel. Rv has unsuccessfully been repaired twice by Grand Design SRT & three times at Grand Design Factory. Independent RV service repair shop identified further damage caused by Grand Designs failed attempts at repair.

I am submitting a new safety complaint regarding my 2021 Grand Design Solitude 380FL, VIN [XXX] . On my first trip out this year (4/29/2026), while towing approximately 20 miles to a nearby campsite, the off-door-side cargo compartment door again opened during transit. As a direct result, a bucket containing my water hose, regulator, 90 degree fitting, etc were ejected from the compartment and onto the roadway at highway speed. This is a significant escalation of the safety issue previously reported. This is no longer limited to a door opening condition—this event resulted in unsecured cargo being discharged into a public roadway, creating a hazard to other motorists. This failure occurred despite extensive prior repair efforts, including: Four separate Service Response Team (SRT) visits Approximately 10 weeks at the Grand Design factory for structural and frame-related repairs Multiple inspections and repair attempts involving both Grand Design RV and Lippert Components The cargo door opening condition has persisted throughout this entire repair history and has not been resolved. This repeated failure following extensive repair attempts demonstrates that the manufacturer’s inspection and repair procedures have not corrected the defect. The condition remains present and continues to pose a clear safety risk to other motorists on public roadways. This event further supports that: The defect is ongoing and unresolved Prior repairs were ineffective The condition presents a real hazard to public roadways I respectfully request that this incident be included in the investigation record and considered as evidence of an unresolved safety defect with the potential to cause roadway incidents or crashes. I am available to provide photographs, video, or additional documentation related to this event. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I am filing a complaint regarding the frame manufactured by Lippert Components on my 2021 Grand Design Solitude 380FL (VIN [XXX] ). Lippert is the OEM supplier of the frame and has been directly involved in inspection and repair of ongoing structural failures. The unit has experienced repeated structural failures, including frame flex, broken welds, cracking of the main I-beam rails above both axles, torn steel upper sill plates and suspension failures. These issues began within the manufacturer’s warranty period and required extensive factory repairs from December 2024 to February 2025, including reinforcement of the upper deck, weld repairs, sill plate replacement, and added gussets. Despite these repairs, new failures developed shortly after. In September 2025, a Lippert technician (dispatched at Grand Design’s request) identified new frame cracks above both axles, a bent outrigger support, and repeated suspension failure. These were not pre-existing conditions but occurred after factory structural repairs. In December 2025, Lippert performed additional field repairs, including welding the cracked frame, adding fishplates, reinforcing outriggers, and installing cross-members. These repairs were performed under engineering direction, and Lippert confirmed no standard TSB applied to this condition. Despite multiple repair attempts, the unit continues to exhibit structural-related issues, including cargo doors opening during transit and recurring suspension failures. These conditions indicate ongoing and unsafe frame deflection and instability. Grand Design has now stated their repairs are done per a customer satisfaction campaign, and attributed responsibility for any ongoing frame issues to Lippert, and has abandoned any further assistance with cargo doors opening during transit. This represents a systemic structural defect affecting safety, including risk of debris or components entering roadways and loss of structural integrity during travel. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION

I was informed to reference this code PE24029. 2021 5th Wheel - Grand Design Solitude 310GK. Frame cracks and separation. June 2025, contact made with Grand Design and they approved for us to obtain a welder. We did. It did not correct the issue and we contacted Grand Design again. Our Unit has been in the repair shop since December10, 2025. Back and forth emails with Grand Design. Sides need to be taken off to get to frame issues and make a repair. Would love for representative from NHTSA to come and look at our unit. The lower portion has been dropped, and you will be able to view. It's currently, in Santa Fe Springs, CA.

The contact owns a 2021 Grand Design Solitude Trailer. The contact stated that while driving approximately 60-65 MPH, the cargo doors opened independently. Additionally, the contact stated that the built-in tables were detaching from the wall, and the wall panels were separating in the bunk room. The contact also noticed that the walls were separating from the floor. The contact related the failure to NHTSA Action Number: PE24029 (Structure). The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The manufacturer was not notified of the failure. The failure mileage was unknown.

Current Symptoms (post-repair): Excessive Frame Flex: - Pin Box Flex, including cracking sounds - Bulge in bottom corner of front driver side slide - Decal ripples - Screws snapping - Door alignment issues - Sawdust on interior furniture after moving - Pinch molding issues - Screws backing out Repairs were made on the unit in Feb 2025, however the above symptoms are still present (or have worsened) since the repair was completed.

On the evening of 7-1-25 we had finished unhooking the rv. As we were setting out our leveling blocks we noticed smoke pouring from the front battery compartment. After we had disconnected our batteries via the battery disconnect switch and removed the batteries we were able to search out the cause of the smoke . The power cable from the tow vehicle where it makes connection to the camper was inserted into a metal box. The connector to the box had come free allowing the cord to rub through and short to ground on the metal box causing the wire to burn back through the wire bundle into the battery compartment. This melted all the wires in the bundle and fused them together . There appears to be no fusebile links in line to protect against thermal overload. If we had not been parked and unhooked we would not have been able to respond so quickly to disable the battery power .