28 of the
207 complaints filed about the Grand Design Reflection
are about the suspension —
14% of everything owners reported.
The worst model year for it is 2017.
We purchased the coach fall 2022. First major trip was in summer 2023. The main slide out failed (stopped working halfway out and would not extend or retract) the second night of camping. There was not a local repair facility available. A mobile repair person was able to get the slide out retracted. He informed us there was only one screw holding the main slide out frame in place. We wrapped a ratchet strap around the coach to hold the slide out in so we could at least continue our trip. A remote repairman at out next stop reported this is a common occurrence on this coach and it would need to be completely rebuilt. We noted that during transport there was sawdust on the cabinets and floors which we have been informed is evidence of excessive frame flexing. We took the coach back to the dealer from which we purchased the unit. The slide out had to be completely rebuilt (new rails, new slide blocks, new motors). We have little confidence that the slide out will not fail again. We noted that the rear tires were wearing at a rate of more than 4 times faster than the front tires. The excessive wear was accompanied with concern that we would blow a tire on the road and cause an accident and/or injury. A Lippert representative was consulted who advised that the front axle was defective and had to be replaced. Our extended warranty did not cover the cost of the axle. The next major trip was in summer 2024. The main slide out failed again. A repairman noted that the motors and rails needed to be replaced again and that the frame was at the limit of being within specs and may have contributed to the problem. During that repair the repairman noted cracking in the roof seams at the major junction at the front of the camper and around AC units and vents. Each of those areas had been resealed just 5 months earlier. We were informed that this was also evidence of excessive frame flexing. The repair facility diagnostician reported that the roof needed to be scraped and resealed.
NHTSA complaint #11649791 — an unverified report by a vehicle owner.
The Driver side rear outer wheel bearing seized and the wheel including drum came off the axle while driving about 30mph. The wheel rolled down the road but fortunately did not hit any other vehicles. The RV was towed to RV dealership. Dealership could not determine root cause of failure. The RV had approximately 10,000 miles on the trailer before incident. The bearings has been inspected and repacked prior to trip by certified RV tech. Before trip started RV was weighed at CAT certified truck scale and combined rear axle weight was 9200 lbs. Each axle is rated at 5200 lbs. Owner of RV contacted Dexter Axle, the manufacturer of the axle. As a second owner, warranty was no longer valid. Dexter representative did state that the replacement 5200lb axle outer bearing has been changed to a larger bearing. The representative stated that the reason for change was not due to reported failures but consolidation. The owner had both axles replaced with 6000lb axles and has driven 1250 miles since incident.
NHTSA complaint #11633318 — an unverified report by a vehicle owner.
While returning from a recent camping trip my wife while following the trailer home noticed the house structure was swaying and bouncing too much. She had thought the rig would fall apart. We arrived home and notice that the slide was out 2-4 inches, the cabin door had opened, an interior wall had separated from exterior wall and a side wall had flexed 2 or more inches out by another slide. There was bends and creases in the exterior metal side skirting that needed to be secured for travel. on approximately 11/04 we turned in the rig for repairs to Happy Daze RV. They Have since made us aware of frame cracks through out the trailer. We have not been notified of who or how the repairs will be handled.
NHTSA complaint #11628876 — an unverified report by a vehicle owner.
I habe a 2021 Grand Design Reflection 303 RLS. The frame is cracked on both side just above the center spring shackles, I have also noticed frame flex between the pin box of the hitch and the rv body. I noticed the cracks when setting up the rv for the weekend and the frame flex driving down the road. I do not have any pictures of the cracks, but did attach a document to reference the frame crack and procedure to repair. The rv is at the dealership now being evaluated.
NHTSA complaint #11626711 — an unverified report by a vehicle owner.
In 2021, we began noticing wall movement in the interior of the RV, fasteners, paneling and interior walls getting loose and moving. After more trips we noticed scratches in the flooring and wood chips laying on the interior floor when we would push the main slide out. We also began noticing the large slide didn’t seem to be closing tight to the outside wall on one end. After more inspection we noticed large roller marks appearing on the underside of the main slide. We scheduled our unit into the dealership for review. The Dealership identified bent frame rails, twisted spring hangers, frames cracks, bent outriggers on the frame supporting the outside walls. The dealership contacted the manufacturer and the manufacturer sent one of their service repair technicians (SRT) to my dealership for an inspection. Because we have heard and seen issues with broken springs, spring hangers and the risk they create from losing springs, wheels and axles etc. the dealership advised that using the RV was not an option until the manufacturer approved it for use. As a result, several trips were cancelled for potential safety reasons. The SRT and the dealership believed that the unit had to go back to the factory for inspection and proper repairs. The unit has gone back to the manufacturer and the frame manufacturer where major frame work has been completed. Now we have a reworked, modified, weak frame and based on the report I’ve seen from the frame manufacturer I’m concerned that they didn’t go far enough and only worked on adding support to 4 of the 6 spring hangers and the related frame areas. It appears that the work done to fix the frame has raised the overall height of the unit 2 -3 inches and added weight to the unit which affects the weight sticker on my RV. I have asked but still haven’t received an engineering specification that dictated the work done to the frame to help build confidence and make this a safe and reliable RV.
NHTSA complaint #11625771 — an unverified report by a vehicle owner.
The entire rear section/walls of the camper have lifted and separated from the main frame. A licensed RV specialist has inspected the unit, and determined the main frame has severe issues and the unit should not be used or moved. There were several warning signs brought to the attention of Grand Design but they dismissed it as being within 'tolerance'. I'm a licensed contractor of 39 years and proved to them there is a major issue, but even their own service response technician dismissed it as being in 'tolerance'. Now it has turned into a catastrophic failure. I demanded Grand Design come and take it away. I let them know it has major failure and is a safety hazard, they sent a driver to tow it back to their factory, I even let the driver know it should not be towed because the entire body at the rear has separated from the frame and could detach causing further risk to him and others. They didn't care, and away it went. Mine isn't the only one. There are several other I found out about that the body was detaching from the frame.
NHTSA complaint #11587981 — an unverified report by a vehicle owner.
Own 2018 Grand Design (GD) RV with a broken Lippert (LCI) spring hanger that holds the axle in place, not discovered until maintenance. Photos available. Research reveals longevity, LCI knowledge, fix, number of & lack of notification. Contacted dealer, GD & LCI about safety defect told “Out Of warranty.” Not warranty, safety. The GD RV requirement or LCI frame equipment component issue is the spring/axle hanger. Other RV manufactures utilize Lippert frames with the same component/condition. LCI RV frames experience a higher rate of spring/axle hanger failures than RV manufactures Northwoods or Outdoor RV that design and construct their own RV frames. Info GD Forum. Attached #1, 2, 3, 4. There are more. 7/2014 NHTSA Recall # 14V-288 Starcraft. #5 10/7/2016 Keystone Rv RECALL: 14V-146 Safety Advisory: 14-205. #6 4/ 23/2021 LGS Industries Inc, #7 Recalls based on quality. Current cause unknown, “may fail during travel leading to an increased risk of loss of control and vehicle crash” remains the same. March 6, 2022, post describes in detail the broken spring hanger issue, includes a mechanical drawing dated 2003 of Lippert designed V modification fix. #8 LCI Publication LIP-0135 revA, AXLE RETRO PROCEDURE developed for 2009 Open Range RV. Page 2, information/drawings how to modify spring hanger, with V mod. #9 On 12/2020, a post “This is what the spring hanger looks like with the V reinforcements factory installed on my ’21 31G.” Is Lippert now installing the V mod on new frames? #10 Educating RV owners, the importance of inspection & available V mod of potential hanger failure, would result in safer roads for owners & public. GD & LCI’s current absence of responsibility & involvement is unfair.
NHTSA complaint #11587832 — an unverified report by a vehicle owner.
Took delivery of this new 2024 on [XXX], 2024. There has been a know problem with the rear stabilizing jacks being installed too long. Lippert is the manufacture of the jacks and their specifications require that the rear jacks be at least 7" from the ground in travel mode. Mine measure 3-5" from the ground when attached to the truck and level. This creates a a dangerous issue if a jack strikes the ground during travel and comes loose. It was conveyed to me that Grand Design made changes to this by installing a shorter rear jack system beginning in March of this year which did not happen on this unit. This is the correspondence with the dealer that I purchased from when I inquired about the potential jack issue prior to the sale. .................. We just spoke with our Reflection Rep and he says that Lippert has taken care of the jack issues and there shouldn't be anything for you to worry about concerning them. If you have any other questions in the meantime, let me know! Thanks, Jordan Land INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11587162 — an unverified report by a vehicle owner.
The contact owns a 2023 Grand Design Reflection RV. The contact stated that the RV was designed with an electric leveling system. The contact stated the two rear levelers failed to elevate beyond 4.5 inches from the ground. The contact stated that the levelers would strike the ground while driving over a speed bump or on a bumpy road surface. The contact stated that the issue was a safety concern because it could cause damage to the RV while driving. The dealer was notified of the failure and referred the contact to the manufacturer for assistance. The vehicle was not diagnosed or repaired. The manufacturer was contacted but declined to provide shorter levelers. The failure mileage was approximately 200.
NHTSA complaint #11558983 — an unverified report by a vehicle owner.
In April 2023 during an inspection to correct a misalignment of my 2019 5th wheel trailer's dual axles, it was discovered by the servicing shop (Straight Line Suspension, Mesa AZ) that the left rear spring hanger had failed causing one of the axles to become misaligned. Straight Line informed me that this was a very unusual situation but we assumed it was a one off situation which was then corrected by Straight Line. On September 24, 2023 while traveling on Interstate 40 in western Arizona several vehicles blew their horns at me and indicated that I should pull off to the side of the road. As I slowed down and began to get out of the active lane I heard a tire blowout. After stopping on the side of I-40 I discovered that the blowout was a result of the right rear spring hanger had broken apart and subsequently hitting the inside of my right rear tire and totally destroying it. At this point the rear of the spring and axle was no longer connected to the chassis. I contacted a towing company who had to chain up the floating axle in order to tow me to the nearest exit. After I located a mobil welder to temporarily patch the broken hanger and was able to limp home with my trailer. I contacted Grand Design and they informed me that since it was over 1 year since I bought the new trailer from them it was out of warranty but suggested that I contact Lippert Components who was the OEM of the defective chassis and spring hanger. Since there are a total of 3 hangers on each side I asked that they pay to replace the broken one plus the other 4 that had not yet broken off. They asked that I get an estimate to replace the broken hanger and the other hanger that I already replaced 5 months earlier. They refused my request to replace the total of 5 hangers that were still part of their original build. If additional hangers had broken loose at that time it is likely that 1 or 2 axles could have broken free from the trailer and possibly cause a catastrophic situation.
NHTSA complaint #11554661 — an unverified report by a vehicle owner.
The rear drop brackets on both sides of the back axle of my 5th wheel RV failed and broke off. The drop brackets attach the leaf springs to the RV frame. While pulling the RV, I noticed a sudden change in how the RV was pulling and it seemed to be unstable. I pulled over and while looking for a cause, I found the broken brackets. I was near a Camping World RV repair store, so I towed it there where the brackets and frame where repaired. Had this occurred at highway speeds, the axle could have become so unstable that it broke the remaining brackets which would lead to a complete loss of the axle on the highway and whatever disaster would occur after that. This definitely would have put other drivers and their families lives at stake. I researched this on the Grand Design owner forum board and found that this same problem has occurred to other RV owners. Looking at the broken bracket prior to repair, it appeared to be an inferior cast metal that didn't seem appropriate for such an important part under stress. I contacted Lippert, manufacturer of the frame, to notify them of the incident.
NHTSA complaint #11548361 — an unverified report by a vehicle owner.
While parked in an RV park I discovered that the right rear spring hanger on my fifth wheel RV had fractured and separated immediately adjacent to a weld line. I am unaware of any incident that can explain this damage, although I did hear a clunk while auto leveling the vehicle at our campsite. (Auto leveling is computer controlled and is a routine operation.) Inspection of the intact left rear spring hanger reveals what appears to be a small crack that may be the beginning of a similar problem on that side. An undetected failed spring hanger when traveling at highway speeds can obviously be a cause of severe property damage and death. Research of this problem in user groups and forums revealed that it is well known to vehicle owners. Anecdotes of broken hangers abound, as do user-invented fixes. Interestingly, Lippert (aka LCI, who is the manufacturer of the vehicle frame) reportedly has a repair for the problem that it has retrofitted to some vehicles and is apparently using in some newly manufactured vehicle frames. The fix is to add a 'V-brace' that is welded to the spring hangers and increases their strength. Example: https://gdrvowners.com/forum/operation/suspension-amp-brakes/52915-spring-hanger-advice There are no recalls for my trailer suspension that I can find, so despite apparent knowledge of the issue the manufacturers of both the frame and the vehicle have failed to warn me or others of it. I am now working with both Grand Design and Lippert to solve this problem on my vehicle. I will press for confirmation that the 'V-brace' is a viable repair that won't violate my warranty and will press to have it implemented on my fifth wheel RV.
NHTSA complaint #11451734 — an unverified report by a vehicle owner.
The contact owns a 2018 Grand Design Reflection. The contact stated that during maintenance of the vehicle, he noticed that the driver’s side rear upper shackle pin on the Dexter trailer axle was not drilled to allow lubricant grease to enter, causing the pin and spring to dry out. The vehicle was not taken to a dealer. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 9,000. Consumer contacted the RV manufacturer, Grand Design, who suggested he follow up with axle manufacturer, Dexter.
NHTSA complaint #11439033 — an unverified report by a vehicle owner.
Noticed the left side of the 5th wheel seemed lower, the smell of burning rubber was highly present. Upon further investigation noticed the front axle leaf spring had broken. Noticed the new tire was hot and rubbed up on and caused damage to the metal of the chassis and ruined the new tire.
NHTSA complaint #11428412 — an unverified report by a vehicle owner.
While towing my rv, the weld that secures the rear axle springs broke. This weld was located on the right rear side of the frame and it snapped completely off the Lippert frame. It allowed the rear axle to move forward and the two tires on the right side contacted each other and the tires started to disintegrate. A tire on the left side was forced out of alignment and the tire shaved rubber until the steel belts were visible. These tires were high grade tires with less than 5000 miles on them. I stopped for fuel and noticed the damage. If I had continued the tires would surely have had a catastrophic failure shortly. This would have certainly resulted in a loss of control and a probable crash at highway speed. Since the tires were rubbing it is also likely a fire could have resulted. I was unable to have the vehicle moved to a repair location and no mobile rv techs would respond since I was in a remote location. I had to hire a local welder to reattach the weld and reinforce the frame on both sides. In speaking with my insurance company it was determined that this is not an unusual problem with welds breaking. The vehicle was not inspected by police as no other individuals or property was involved. Photos of the damage and broken weld were sent to Grand Design and Lippert, the manufacturer of the frame. Photos taken of the repairs performed by the welder were also sent to them. In addition to repairing the broken weld, I had the welder reinforce the left side of the frame holding the axle springs in place so that it would not fail. The unit is now much safer than it was before the repair. There were no warning lights or symptoms for this problem. I stopped purely by chance for fuel and noticed the steel belts protruding through my tires and this is the only thing that stopped a catastrophic failure and probable crash. The trailer has never been overloaded, and was never driven faster than 65. It has never been in an accident.
NHTSA complaint #11422612 — an unverified report by a vehicle owner.
I WAS DRIVING IN ARKANSAS IN OCTOBER 11TH 2019 WHEN I NOTICED THE RV DID NOT APPEAR TO BE TRACKING STRAIGHT BEHIND THE TRUCK. I PACKED UP AND LEFT THE CAMPGROUND ABOUT 2 HOURS EARLIER. THERE WERE NO ISSUES WITH THE AXLES AT THAT TIME. THERE WERE NO UNUSUAL ROAD HAZARDS OR SHOCKS TO THE FRAME DURING THAT PERIOD PRIOR TO WHEN I NOTICED THE ISSUE. I STOPPED AT A REST AREA IN HELENA ARKANSAS AND FOUND THE RIGHT REAR AXLE SPRING HANGER HAD BROKEN FROM THE FRAME. THE SPRING AND REAR AXLE WAS SHIFTED TO THE LEFT AND LODGED PRECARIOUSLY UP INSIDE THE FRAME. IT WAS LATE ON A FRIDAY EVENING. I WAS ABLE TO FIND A TRUCK/TRAILER SHOP OPEN IN BATESVILLE, MISSISSIPPI. I DROVE THERE FOR EMERGENCY REPAIRS. THEY JUDGED THE FAILURE WAS DUE TO POOR WELDS. I'VE DONE SOME WELDING AND IT WAS EASY TO RECOGNIZE POOR PENETRATION. THE TRUCK SHOP WELDED THE HANGERS AND PULLED THE REAR AXLE AS CLOSE TO PROPER ALIGNMENT AS POSSIBLE. HOWEVER THE AXLE HAD SHIFTED SLIGHTLY IN THE U-BOLTS. THE U-BOLTS NEEDED TO BE CUT OFF, THE AXLE PROPERLY ALIGNED AND NEW U-BOLTS INSTALLED. THEY DID NOT STOCK THE BOLTS BUT THE TRAILER WAS SAFE TO TOW HOME. UPON RETURNING FROM THAT TRIP, I PUT THE TRAILER IN MY WAREHOUSE AND INSPECTED THE FRAME AND AXLES. I NOTICED IMMEDIATELY THE FRAME AT THE RIGHT REAR CORNER DIRECTLY BEHIND THE FAILED REAR AXLE SPRING HANGER HAD SEPARATED. THE EXTERIOR SHEET METAL IS WARPED AND THERE IS A VISIBLE GAP. THE FACTORY HAS REFUSED TO COVER THE AXLE REALIGNMENT OR RIGHT REAR FRAME SEPARATION UNDER THEIR 3-YEAR STRUCTURAL WARRANTY. MY RV HAS BEEN AT THE DEALER JUNE 5, 2020 UNTIL TODAY OCT 1 REGARDING THESE ISSUES AND AN UPPER DECK FRAME ISSUE THAT THEY FAILED TO REPAIR CORRECTLY 2 YEARS AGO.
NHTSA complaint #11362230 — an unverified report by a vehicle owner.
THE RIGHT REAR LEAF SPRING HANGER FOR THE REAR AXLE BROKE OFF FROM THE TRAILER FRAME, THIS HAPPENED WHEN VEHICLE WAS IN MOTION ON THE HIGHWAY. NOTICED REAR AXLE OUT OF PLACE WHEN WE WERE PARKED IN OUR DRIVEWAY UPON FURTHER INSPECTION THAT IS WHEN WE NOTICED THE RIGHT REAR HANGER BROKEN COMPLETELY OUT OF FRAME AND THE LEFT REAR HANGER CRACKED.
NHTSA complaint #11360350 — an unverified report by a vehicle owner.
PULLING IN FOR GAS AT GAS STATION HIT THE CURB MAYBE 2 MILES AN HOUR WITH LEFT FRONT TIRE BENT FRONT TIRE ON LEFT BENT HANGER ON LEFT AND BENT HANGER ON RIGHT CAUSING TIRE TO POP AND OVER 3000 DOLLARS OF DAMAGE TO SUSPENSION. HAD ABOUT 1300 MILES ON TRAILER WAS FIRST TRIP OUT
NHTSA complaint #11217271 — an unverified report by a vehicle owner.
THE SUSPENSION HANGER, THE PIECE THAT HOLDS LEAF SPRING AND IS ATTACHED TO THE FRAME OF THE TRAILER, BROKE CLEAN THROUGH ON INBOARD REAR PASSENGER SIDE OF THE VEHICLE. THE SUSPENSION FAILURE WAS DISCOVERED WHILE PARKED AND DURING ROUTINE LUBRICATION OF THE SUSPENSION WET BOLTS. THE COMPONENT IS AN INVERTED U BRACKET, THE TOP OF WHICH ATTACHES TO THE TRAILER FRAME, THE ARMS OF WHICH, IN CONJUNCTION WITH A WET BOLT PROVIDE THE MOUNTING LOCATION FOR THE REAR EYE OF THE LEAF SPRING. ONE LEG OF THIS U BRACKET, AND CONSEQUENTLY ONE END OF THE BOLT ATTACHING THE LEAF SPRING TO THE BODY COMPLETELY FAILED, BREAKING CLEAN AWAY FROM THE FRAME. UPON FURTHER INSPECTION THE REAR DRIVER SIDE LEAF SPRING BRACKET HAS DEVELOPED A CRACK, BUT HAS NOT PROPAGATED THROUGH THE ENTIRE ARM OF THE BRACKET. FORTUNATELY THIS SUSPENSION FAILURE WAS DISCOVERED WHILE THIS 10,000LB VEHICLE WAS PARKED AND FAIRLY EARLY AS THE ARM OF THE SUSPENSION HAD NOT YET HUNG TO A HANGING POSITION. WITH THE OTHER HANGER BEGINNING TO FAIL, THIS VEHICLE WOULD POSE A SIGNIFICANT HAZARD TO PERSONS AND PROPERTY WHILE TRAVELING AT HIGHWAY SPEEDS. THE VEHICLE IS LESS THAN 2 YEARS OLD, IT HAS BEEN TRAILERED LESS THAN 3000 MILES, HAS BEEN LOADED WITHIN GVWR LIMITS, HAS NEVER BEEN IN AN ACCIDENT, HAS SUSTAINED NO BODY DAMAGE. *DT CONSUMER CONTACTED MANUFACTURER OF THE FRAME AND SUSPENSION COMPONENTS. CARFAX CANNOT PROCESS THIS REQUEST.
NHTSA complaint #11209790 — an unverified report by a vehicle owner.