2022 Grand Design Solitude

On January 18, 2026, while towing my 2022 Grand Design Solitude 310GK near Bouse, Arizona, I discovered a serious problem and pulled off the road. The rear axle had become detached/displaced. At the time, I did not know exactly what had occurred or what caused the axle event. The RV was subsequently delivered to a repair facility on March 27, 2026. During the repair process, significant structural/frame damage was progressively discovered, including cracking in the spring-hanger/frame area. The repair facility documented that the damage was more extensive than initially believed and performed structural repairs that included additional steel and plating. My insurance company approved $23,615.83 in total repair costs, with a net repair cost of $23,365.83 after the $250 deductible; not all of that amount was frame-related. During this process, Grand Design referred me to Lippert regarding frame repair information. I subsequently received a Lippert frame repair procedure addressing inspection and repair of frame cracking. Grand Design has advised that my RV is not within the date range of the related program. I have asked Grand Design and Lippert to review the documented structural repairs and determine whether they are consistent with Lippert's frame repair procedure and whether the RV is structurally safe for highway use. I have specifically stated that I am not asking them to determine the cause of the January incident or certify the repair facility's workmanship. I am seeking a competent engineering determination concerning the structural/frame condition and repairs. I am reporting this to NHTSA because failure or cracking of the frame/suspension attachment structure on a large towable RV could create a serious highway safety risk. The cause of the January axle event and when the frame cracking developed are UNKNOWN. The cracking was discovered progressively during subsequent repairs.

Documented Symptoms consistent with the conditions described in Grand Design TSB 24-001 1. Dynamic Sidewall Separation – Driver and Passenger Sides The upper-deck sidewall area displays visible movement under load. When the trailer is connected to the truck via the pin box, the exterior trim and sidewall gap noticeably widens. When the trailer is leveled on its landing gear, the separation compresses and partially closes. Additional observations include: •Separation of exterior trim components •Cracked and widening caulk joints •Visible movement beneath both upper-deck slide-out openings These conditions were first observed following an approximately 300-mile round trip completed on August 6, 2026. 2. Front Driver-Side Slide-Out Binding and Incomplete Operation The front living room slide-out now binds within the opening and appears affected by structural distortion. Timeline: •July 24, 2026: Upon arrival at an RV resort, the slide-out stopped approximately halfway during deployment. Retracting and redeploying the room allowed it to complete its cycle. •August 6, 2026: After returning home, unhitching, and leveling the coach, the slide-out again became firmly wedged during extension. It required assistance to retract and return to the closed position. Because of the excessive binding force encountered, I have not attempted to operate the slide again. 3. Front Passenger-Side Flooring Distortion The vinyl flooring adjacent to the upper-deck slide-out area is lifting, rippling, and bubbling. This condition appears indicative of structural movement and subfloor shifting rather than a cosmetic flooring issue. 4. Sawdust Present in Cabinets The unit is available for inspection, appointment scheduled for 8/19/26. No one has inspected this unit at this time, no warning lights or other symptoms prior. The first discovery of failure was on 7/24/26. Due to the symptoms and consistent with the TSB, this unit poses a safety risk to myself, family and other motorists.

I own a 2022 Grand Design Solitude 346FLS fifth wheel trailer. The trailer has been at the dealership for over nine months after structural frame cracks and weld separations were discovered during inspection. The cracks appear in structural frame components and welded areas supporting the chassis. This raises concerns about the integrity of the trailer frame during towing and braking. In addition to the frame defects, all four leaf springs in the suspension system have failed or lost structural integrity. This suspension failure presents a safety risk because it affects axle alignment, load support, and trailer stability while towing. The trailer manufacturer (Grand Design) and dealer have been notified, but the unit has remained out of service for an extended period while the manufacturer decides how to address the problem. Structural frame cracking combined with suspension failure represents a serious safety concern for a towable RV traveling at highway speeds. I am submitting this complaint so the issue can be investigated for potential defects affecting other trailers of this model or similar models.

Weak bedroom floor. Screws backing out of bedroom floor and poking through flooring. Front nose cap separating from body. Broken screws on front nose cap. Pin box flex. Buckled wall in bunk slide out room. Main living space floor is bowing down where it meets the walls causing main door mis-alignment and the stairs to cause marks on the flooring etc.

• Cracks in the Pin Box: A reputable RV dealer/shop has identified significant cracks in the pin box, indicating a serious structural compromise. • Slide-out failures: The GIBs on the slide-outs have broken, causing them to extend while the RV is in transport on highways. • Cargo door malfunctions: Cargo doors are repeatedly popping open during highway travel. • Main entry door instability: The front door and screen are not operating correctly, preventing proper closure and causing the door to open unexpectedly during transport. • Structural fastener failure: Screws and bolts are detaching from the unit during transport. • Front cap detachment: The front cap is popping open at the fifth-wheel hitch area and exhibiting significant sway during transport. These issues collectively indicate a severe underlying problem with the structural integrity and frame of the 2022 Grand Design Solitude, creating hazardous conditions for both the occupants and other road users. I urge NHTSA to investigate these defects thoroughly to prevent potential accidents and ensure consumer safety.

While performing a factory recall on the RV, the mobile RV tech discovered underlying issues. He suggested that we get an in-depth evaluation. I contacted and dropped the RV at the shop for diagnosis. The shop discovered extensive frame damage (weld break) at the main beam connecting the pin box and also total frame break and separation on the upper deck floor support. There is substantial floor sagging above the outriggers extending from the living area through the back of the RV. The whole rear of the RV is sagging, causing wall cracking and slideout damage. The shop also measured a considerable deflection (pin box to front bottom frame) while performing the manufacturer's instructions for the measurements. The manufacturer has denied our claim and we are tasked with getting home to permanently park the RV. The manufacturer communicated with the shop regarding their finds and the denial, but has not contacted me in any way. All recalls/TSBs have been performed. The rear TSB has not fixed the rear frame sagging and the front TSB was not 100% completed by a dealer, in that several lag bolts were not replaced and none of them had adhesive applied. We have been fortunate that we have had no doors open while traveling. I composed a list of the items we found and submitted it with photos to the manufacturer. They said that the RV qualified for the "Customer Satisfaction Campaign" and that it should take ~1hr for a visual inspection. They only paid 0.10 hrs.

We bought our 2022 Grand Design Solitude 346FLS-R in March 2023. We have had numerous safety issues and concerns, and currently don’t feel safe towing it. 1. External locked compartments and entry door open while traveling. Risks: distraction, collision (passing vehicle or objects), quick maneuvering (to side of road), contents ejected onto road/vehicles. Resolution: Shops have tried to fix, but problem continued. I placed some screws to extend the latch plates. Concerned this is a “frame flex” issue, along with our floor separation, sheared screws, saw dust, etc. 2. Three axle/suspension failures. In 3/2024 and 12/2024, sudden/extreme tire wear was noted due to failed suspension (broken leaf springs, cracked equalizers). In 8/2025, while driving on [XXX], an entire wheel disappeared. We called the MI highway department afterwards and they had no reports of accidents or debris due to the wheel. Roadside assistance got us to a local repair shop that found the 3 other tires were badly worn/damaged, rear passenger side leaf spring cracked (3rd time), and remaining brakes "fell apart in chunks". The technician diagnosed a bad spindle. As the work was completed, the shop owner stated "I don't think your suspension is fit for this rig. It already appears max'd out." Risks: The entire wheel flying off on the highway could have easily killed someone. Suspension failure while rolling could lead to tire blowouts/catastrophic damages/major accident. Resolution: Suspension repairs made/tires replaced. Recently stopped in at Grand Design in Elkhart, IN to speak with the Customer Service Director about these safety issues. The GD shop is booked until December, but a frame and suspension inspection at a GD dealer was authorized. CW Direct in Elkhart completed the inspection, found a frame crack and assessed the 7K suspension as insufficient. Still no resolution and we now have not been able to live in our home for over two weeks. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2022 Grand Design Solitude RV. The contact stated that while driving 65 MPH and hauling the RV, the rear passenger's side tire of the RV experienced a blowout. The contact was able to pull over to the side of the road. The contact replaced the tire with a regular-size spare tire; however, the rear passenger's side tire experienced a second blowout while driving on the same day. The contact stated that the tire failures caused damage to the RV. The vehicle was taken to the dealer, where it was diagnosed with frame flex, frame steel fracture, and missing screws around the hitch, and unparalleled axles. The RV was not repaired. The manufacturer was notified of the failure, and a Grand Design technician confirmed that the RV was experiencing excessive frame flex, which the contact related to the tire failure. The manufacturer recommended towing the RV to one of their locations for frame repairs, but the contact was advised that the repair of the axle damage caused by the tire failures, prior to towing the vehicle, would be paid for out-of-pocket. The RV was not repaired. The failure mileage was approximately 20,000.

The contact owns a 2022 Grand Design Solitude. The contact stated while driving at an undisclosed speed, the doors unlatched and opened. The contact stated that the bolts were missing, the furniture moved, and the walls shifted. While driving at an undisclosed speed, the RV failed to drive in a straight line. There were no warning lights illuminated. The vehicle was taken to the local dealer where it was diagnosed with fractured slides and failure to the frame. There was an unknown diagnosis related to the suspension. The vehicle was repaired to the original specifications, but the failure recurred. The manufacturer was not contacted. The failure mileage was unknown.

The contact owns a 2022 Grand Design Solitude. The contact stated that while pulling into a campground she was informed to check the tires. The RV was taken to a tire center where it was discovered that the brakes had crumbled and there was a spring inside. Additionally, the equalizer was cracked. The contact stated that while driving 75 MPH on the highway, a wheel on the RV detached. The RV was taken to an independent mechanic who determined that the axle was cracked. The local dealer was contacted several times. The RV was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 10,080.