2023 Grand Design Solitude Recalls & Complaints

Incident: September 23, 2026 · Filed: October 9, 2026

The RV roof experienced a substantial failure in which the membrane peeled back, exposing the underlying OSB roof decking. A subsequent inspection identified additional concerns regarding the materials and fasteners used in the roof assembly. I believe these findings warrant investigation into whether the RV was constructed in accordance with the manufacturer's specifications, applicable installation requirements, and reasonable standards for a weatherproof recreational vehicle roof. Before a recent trip, I inspected the roof and observed no visible tears, holes, or obvious membrane damage. After traveling to a new location, I discovered the damage on September 23, 2026. A substantial section of the roof membrane had separated and peeled back, exposing the OSB decking beneath it. The extent of the separation was significantly greater than a localized puncture or small tear. The fact that the roof appeared intact before travel and was subsequently found with extensive membrane separation raises concerns about an underlying weakness in the roof assembly, including the possibility of improper membrane attachment or failure of the roof-edge fasteners. The subsequent inspection performed by a licensed RV technician identified the following specific concerns: At the joints between sections of OSB roof decking, the manufacturer used drywall tape rather than the appropriate seam-sealing tape or sealing system intended for the roof assembly. The inspection also identified steel screws around the roof perimeter and roof rails that had corroded, broken, or loosened. These fasteners were not stainless steel or an appropriately corrosion-resistant alternative. Corrosion and loss of fastener integrity appear to have compromised the roof-edge attachment. Similar steel fasteners were reportedly used at the front-cap seam. These fasteners also exhibited corrosion and had broken or loosened. The condition of these fasteners raises additional concerns regarding the integrity.

Incident: June 11, 2026 · Filed: September 1, 2026

Frame and structural integrity/towable RV. 7/15/2024 — First Warranty Repair (Frame): Blue Compass found broken seal-plate welds on the frame; welds repaired, bolts replaced. 30 ft of roof membrane, which had pulled loose and "ballooned" in transit, was fully replaced. 6/2026 — Recurrence: Roof membrane pulled loose again during travel. Mobile tech (Mike's RV Repair, GA) performed a temporary repair ($668.60, GD-reimbursed), initially noting "frame flex" based on owner's account of 2024 history, later revised to "possible frame flex" absent independent diagnosis. 6/19–21/2026 — Follow-up Repair: GD/dealer deemed mobile-tech photos insufficient. Blue Compass Charleston reopened the repair, found membrane improperly tucked under the front cap, corrected and resealed it. Cost: $1,375.08. 7/23–8/8/2026 — Inspection, No Cause Found: Blue Compass Prescott Valley performed a free inspection; air test found no leak source. At pickup, service writer and tech visually compared the unit to a new one on the lot and confirmed filon flex/loose pin-box fit, expressing concern, but had no authority to independently request Grand Design SRT involvement. 8/10/2026–Present: Owner escalated to Grand Design; new case #01085558 opened for frame flex. GD committed to 24–48-hr follow-up; deadline passed with no contact. Additional structural symptoms since observed: lag bolts replaced in 2024 frame repair are missing, backed out or loose, detached service bay shell, separated closet panel with exposed insulation, misaligned closet doors/wall gaps, screws backing out throughout the basement — suggesting a broader chassis/structural issue beyond the roof. Documentation available: repair invoices, photos/video, mobile tech invoice, receipts, full GD case history. Have an appointment on 9/4/26 for dealer to do a frame inspection that Grand Design and Lippert are requiring to be done before considering any support with repairs.

Incident: May 3, 2026 · Filed: May 4, 2026

The contact owns a 2023 Grand Design 5th Wheel. The contact stated that the propane gas pigtail was on the floor and created an electrical spark and popping noise that traveled up to other cords. The contact stated that the pigtail cord was improperly fitted and should not have been on the floor. The vehicle was not diagnosed or repaired. The manufacturer was not notified. The failure mileage was unavailable.

Incident: November 17, 2025 · Filed: February 3, 2026

This report details a suspected major structural frame failure on my 2023 Grand Design Solitude 391DL. The issues, which are progressive and worsening, indicate a severe loss of structural integrity in the front gooseneck and upper deck area of the fifth wheel. Key observations and symptoms include: Interior Wall Deformation: Interior wall panels in the front bedroom are visibly buckling and warping under stress. Separation of Wall Panels: The rear wall panel inside the main bedroom closet has developed a significant gap and is separating, believed to be a direct result of excessive frame flex. Misalignment of Door Frames: The door frame for the front closet housing the washer and dryer has spread apart to the point where the door can no longer latch or close properly. This demonstrates a clear deformation of the coach's superstructure. Audible Structural Noise: The floor in the front bedroom section produces constant, loud creaking and groaning sounds when walking on it, consistent with a compromised frame and subfloor structure. Safety Concerns: The progressive nature of these failures raises significant safety concerns regarding the vehicle's roadworthiness. The loss of structural integrity in the gooseneck area could lead to a catastrophic failure while the vehicle is in motion, posing a severe risk of detachment, loss of control for the tow vehicle, and danger to other motorists. The integrity of critical components like the roof, slide-outs, and heavy appliances is also compromised. This issue appears to be consistent with a pattern of similar frame-related failures reported by other Grand Design owners, which are the subject of an ongoing class-action lawsuit. I urge the NHTSA to investigate this critical safety defect before it results in a major highway incident.

Incident: August 19, 2025 · Filed: November 19, 2025

The contact owns a 2023 Grand Design Solitude RV. The contact stated that while hauling the RV and depressing the brake pedal to stop, the RV pushed up against the rear of the pickup truck. The vehicle was taken to the local dealer, who discovered that the RV brake shoes had crumbled and failed. The contact was advised that the brake shoes and braking system needed to be replaced. The vehicle was later taken to the local engineering firm and the braking system was replaced. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 9,300.

Incident: October 1, 2024 · Filed: July 21, 2025

Frame Flex & Water Intrusion - We first noticed movement back in August 2024. It seemed like the tongue was going to come through our back truck window where I sit to work with our 3 cats. The inside of the Solitude is a mess too with lights coming down from ceiling, doors are all scratch from rubbing while be transported, trim coming off, wall paper being torn apart, had lag bolts coming up through the floor, leakage in master bedroom, floor warping and more. We took it in to have it fixed in November 2024 to only get her back in late march of 2025. They had to weld and reinforce frame but would not admit to frame flex or provide me with an updated weight placard so it's like they don't want evidence on it. They had to replace the whole floor which meant they had to take off slides to get everything out and now she is back up there with severe water intrusions from slides and other things again. Moisture reader is reading in places between 30 to 48% but Grand Design is denying any water intrusion even thought they took slides out. They only respond after an email is sent. This is unacceptable and hope that one day we can get these RV manufacturers to follow same rules as a vehicle. Why are they all in IN - they have the most laxed laws governing recreational vehicles. Our lives are in danger while driving these RV's on US highways which means we are putting others in danger too. Why aren't they held to a higher standard...where is the safety in all of this. I have pictures all everything if needed for documentation. Thank you for your time.

Incident: May 1, 2025 · Filed: June 12, 2025

The frame has possibly broken in the hitch area. This is a large 5th wheel trailer.

Incident: October 1, 2024 · Filed: June 11, 2025

All brakes were replaced after the first failure. Pulled 3445 miles. RR brake fell apart. Causing loss of braking from that wheel.

Incident: May 1, 2023 · Filed: June 11, 2025

RF brake assembly fell apart. Causing loss of braking on that wheel.

Incident: March 29, 2025 · Filed: March 30, 2025

After my refrigerator stopped working, I pulled the refrigerator out to investigate and check fuses (a common issue) I observed the wiring connected very poorly, and was melted together. additionally, there was a burn mark 2 inches or more in diameter on the wall where these wires were touching. so there was a fire due to this wiring