2022 Grand Design Transcend

1. Complete Trailer brake system failure due to incorrect wire gauge used during assembly at Grand Design. 2. Frame failure at axle shackle weld on Lippert frame due to over-penetration. While towing the trailer there was a message on the tow vehicle information center "trailer Brakes disconnected". All trailer breaking was lost while going down the Siskiyous. At that time the trailer began to sway and was difficult to maintain control due to the loss of trailer brakes. During assembly Grand Design used 18-gauge wire to connect the 14-gauge wire from the brake magnets and axle tube to the wire running through the trailer underbelly up to the Vehicle plug. Lippert brake installation manuals for 4 brake systems state to use at least 14-gauge wiring. These manuals are readily available on the Lippert website. The photos we have provided clearly show 18 gauge was used and its insulation had melted exposing the center conductor. Repair documentation from the dealership to fix the brakes indicated that the right rear magnet was intermittently bad drawing high current which would draw all the braking system current to that one assembly. This maximum current to one set of wiring caused the smaller 18-gauge wire to melt off its insulation which resulted in a hard short that prevented all braking at a very inopportune time. Had 14 gauge been used we would not have lost all braking to the trailer. During the brake wire repair at the dealership the frame around the RR axle shackle failed when the trailer was jacked up. It appears that the shackle attachment weld over-penetrated the frame ultimately causing a weak joint and lead to the frame failure. The frame failing around the shackle weld happening at the dealership instead of on the road is beyond lucky and avoided another very unsafe incident on the road. These two items happening at the same time almost resulted in a multi vehicle crash on I-5 southbound.

We were driving home from the Denver area on Sunday, [XXX] at [XXX]. After about 15 minutes of driving, another driver pulled alongside and told me a tire was missing. I pulled over. One of the trailer tires (driver side, furthest back) was gone. It was nowhere to be seen. The bolts holding lugs nuts were sheared off and the trailer fender was broken. The tire must have damaged the fender when it came off. -The tire assembly malfunctioned - this is only over a year old. -As for safety, the loose tire could have caused major damage. I had no way of knowing it came off since we have dual axles. -I have not taken this into the dealer yet. I called roadside assistance, but it was closed because of the day being a Sunday. I did call an emergency service to repair the wheel, axle, brakes, etc. -I am working with our insurance company and the dealer - no luck so far. They have not inspected it yet. There were no warnings - thank goodness someone told me it was missing. Thanks for consideration of our dilemma. [XXX] - INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)