2023 GRAND DESIGN MOMENTUM

EQUIPMENT:RECREATIONAL VEHICLE/TRAILER:MATERIALS:FLOORING

Grand Design RV, LLC (Grand Design) is recalling certain 2023-2025 Momentum fifth wheel trailers. The interior step base does not adequately support the step tread.

Risk: The tread may detach from the step, increasing the risk of a trip and fall injury.

TRAILER HITCHES

Grand Design RV, LLC (Grand Design) is recalling certain 2022-2024 Momentum 23G and 25G travel trailers. The installed safety chains are underrated for the Gross Vehicle Weight Rating (GVWR).

Risk: Underrated chains can allow the trailer to detach from the tow vehicle, increasing the risk of a crash.

SUSPENSION:MULTIPLE AXLE

Grand Design RV, LLC (Grand Design) is recalling certain 2023 Momentum and Reflection travel trailers, equipped with certain 5200 and 6000 CURT RV axles. The axles may have an improperly tightened grease fitting that can separate and cause damage, possibly resulting in wheel detachment.

Risk: A detached wheel increases the risk of a crash.

EQUIPMENT:OTHER:LABELS

Grand Design RV, LLC (Grand Design) is recalling certain 2023 Momentum toy haulers. The Cargo Carrying Capacity (CCC) label is incorrect. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims."

Risk: Incorrect weight information on the label can cause the vehicle to be overloaded, increasing the risk of a crash.

SUSPENSION:FRONT:SPRINGS:LEAF SPRING ASSEMBLY:U-BOLT, LEAF SPRING TO AXLE

Grand Design RV, LLC. (Grand Design) is recalling certain 2021-2024 Momentum and Solitude fifth wheels, equipped with certain CURT 7000 and 8000 lb axles. The U-bolts may have been improperly tightened, which can cause the axle to move out of position.

Risk: An axle that moves out of position can cause a loss of vehicle control and increase the risk of a crash.

STRUCTURE:BODY:DOOR

Grand Design RV, LLC (Grand Design) is recalling 2022-2023 Momentum fifth wheels. The electric ramp door cut-off switch may allow for continuous power to the ramp door, which can cause the door to fall.

Risk: A falling ramp door increases the risk of injury.

STRUCTURE

The contact owns a 2023 Grand Design Momentum RV. The contact stated that the RV had experienced structural failures with the upper deck bedroom and upper deck bathroom. The contact stated that the RV failure was caused by the frame flex, which caused the floors in the bedroom and upper bathroom to squeak and sag while walking on the floor. The contact also stated that the failure had caused the seal around the bedroom window to become defective. The RV was taken to an RV dealer for repair. The contact sent several letters to the manufacturer about the failure. The contact received a response from the manufacturer that a response from the dealer was needed to proceed with any repair of the vehicle. The contact discovered Technical Service Bulletin: 24-001, which the contact linked to the failure. The RV was not yet repaired. The failure mileage was unknown.

STRUCTURE

The contact owns a 2023 Grand Design Momentum RV. The contact stated that the RV had experienced structural failures in the upper deck bedroom. The contact stated that the RV failure was caused by lag bolts that had backed out and become unsecured. The contact stated that the bedroom nightstand moved and pulled away from the bedroom wall due to the structural failure. The manufacturer and dealer were not yet notified of the failure. The RV was not yet repaired. The contact was informed of Technical Service Bulletin: 24-001; which addressed the failure. The failure mileage was unknown.

STRUCTURE

Overview: This complaint is being submitted in response to alarming and persistent structural failures experienced in our 2023 Grand Design Momentum fifth wheel RV, purchased new in January 2023 from Lazydays RV in Tampa, FL. Despite receiving a factory service bulletin (TSB) and subsequent repairs under warranty, our unit has continued to exhibit excessive frame flex, wall and floor deformation, compromised slide operations, and related structural issues. The failures not only impact the unit’s functionality and safety but raise concerns about a broader systemic issue with the frame design and manufacturing integrity of Grand Design RVs. Our documented repair history and recurring defects suggest these problems stem from substandard frame construction and flex-related design flaws, rather than isolated workmanship errors. Final Remarks: We are not the only owners reporting these failures. Online forums and recent class action filings against Grand Design point to a concerning trend of recurring frame failures that the company appears unwilling or unable to resolve comprehensively. As consumers, we have exhausted all reasonable efforts to seek a resolution through the manufacturer and authorized third-party repair channels. It is our belief that these ongoing frame flex problems represent a safety hazard and require urgent federal oversight and regulatory action to ensure no further units are sold with such defects. We welcome a physical inspection of our unit by NHTSA representatives in the Richmond, Virginia area at your earliest convenience

UNKNOWN OR OTHER

Overview: This complaint is being submitted in response to alarming and persistent structural failures experienced in our 2023 Grand Design Momentum fifth wheel RV, purchased new in January 2023 from Lazydays RV in Tampa, FL. Despite receiving a factory service bulletin (TSB) and subsequent repairs under warranty, our unit has continued to exhibit excessive frame flex, wall and floor deformation, compromised slide operations, and related structural issues. The failures not only impact the unit’s functionality and safety but raise concerns about a broader systemic issue with the frame design and manufacturing integrity of Grand Design RVs. Our documented repair history and recurring defects suggest these problems stem from substandard frame construction and flex-related design flaws, rather than isolated workmanship errors. Final Remarks: We are not the only owners reporting these failures. Online forums and recent class action filings against Grand Design point to a concerning trend of recurring frame failures that the company appears unwilling or unable to resolve comprehensively. As consumers, we have exhausted all reasonable efforts to seek a resolution through the manufacturer and authorized third-party repair channels. It is our belief that these ongoing frame flex problems represent a safety hazard and require urgent federal oversight and regulatory action to ensure no further units are sold with such defects. We welcome a physical inspection of our unit by NHTSA representatives in the Richmond, Virginia area at your earliest convenience

UNKNOWN OR OTHER

This RV has experienced ongoing water intrusion due to faulty manufacturer-installed plumbing fittings and hoses, which allowed leaks into the interior. Moisture has reached electrical wiring, creating a serious fire hazard and contributing to unsafe living conditions. Essential components—including the furnace, refrigerator, and water heater—have proven unreliable or unusable throughout the ownership period. Mold growth has appeared due to the persistent damp environment. This has caused health issues, including respiratory difficulties, headaches, brain fog, and fatigue, with heightened risk due to a pre-existing asthma condition. Structural issues include misaligned exterior doors that fail to seal properly and loud creaking/popping noises during hitching, suggesting possible frame or chassis integrity problems. Equipment failures include a non-functional center awning, persistent sewer odor (suggesting a failed ventilation system), and malfunctioning A/C and heating units. Despite multiple inspections and documented findings from Grand Design–approved technicians, the manufacturer has offered only limited, pre-approved repairs that fail to address root causes. These problems severely impact the safety and habitability of the RV, which is used as a full-time residence. The manufacturer has declined a full inspection, replacement, or buyback. No warning lamps appeared, but symptoms began shortly after purchase and have worsened. The RV remains available for inspection. We request a formal investigation into possible safety standard violations.

ELECTRICAL SYSTEM

This RV has experienced ongoing water intrusion due to faulty manufacturer-installed plumbing fittings and hoses, which allowed leaks into the interior. Moisture has reached electrical wiring, creating a serious fire hazard and contributing to unsafe living conditions. Essential components—including the furnace, refrigerator, and water heater—have proven unreliable or unusable throughout the ownership period. Mold growth has appeared due to the persistent damp environment. This has caused health issues, including respiratory difficulties, headaches, brain fog, and fatigue, with heightened risk due to a pre-existing asthma condition. Structural issues include misaligned exterior doors that fail to seal properly and loud creaking/popping noises during hitching, suggesting possible frame or chassis integrity problems. Equipment failures include a non-functional center awning, persistent sewer odor (suggesting a failed ventilation system), and malfunctioning A/C and heating units. Despite multiple inspections and documented findings from Grand Design–approved technicians, the manufacturer has offered only limited, pre-approved repairs that fail to address root causes. These problems severely impact the safety and habitability of the RV, which is used as a full-time residence. The manufacturer has declined a full inspection, replacement, or buyback. No warning lamps appeared, but symptoms began shortly after purchase and have worsened. The RV remains available for inspection. We request a formal investigation into possible safety standard violations.

STRUCTURE:BODY

This RV has experienced ongoing water intrusion due to faulty manufacturer-installed plumbing fittings and hoses, which allowed leaks into the interior. Moisture has reached electrical wiring, creating a serious fire hazard and contributing to unsafe living conditions. Essential components—including the furnace, refrigerator, and water heater—have proven unreliable or unusable throughout the ownership period. Mold growth has appeared due to the persistent damp environment. This has caused health issues, including respiratory difficulties, headaches, brain fog, and fatigue, with heightened risk due to a pre-existing asthma condition. Structural issues include misaligned exterior doors that fail to seal properly and loud creaking/popping noises during hitching, suggesting possible frame or chassis integrity problems. Equipment failures include a non-functional center awning, persistent sewer odor (suggesting a failed ventilation system), and malfunctioning A/C and heating units. Despite multiple inspections and documented findings from Grand Design–approved technicians, the manufacturer has offered only limited, pre-approved repairs that fail to address root causes. These problems severely impact the safety and habitability of the RV, which is used as a full-time residence. The manufacturer has declined a full inspection, replacement, or buyback. No warning lamps appeared, but symptoms began shortly after purchase and have worsened. The RV remains available for inspection. We request a formal investigation into possible safety standard violations.

STRUCTURE

The contact owns a 2023 Grand Design Momentum RV. The contact stated that while the trailer was parked at a campground, he became aware of gaps in the front body panel. Additionally, the pin box and front landing gear were not leveled with the ground and the primary bedroom had excessive frame flex. The trailer was taken to the dealer, where the front body panel was disassembled, and the bolts replaced. The failure persisted, and the trailer was taken to Great American RV Super Stores (12167 Interchange Dr, Grand Bay, AL 36541), where it was discovered that the front body panel and frame bolts were the incorrect size and the bolts were replaced with larger bolts. The manufacturer was made aware of the failure. The failure mileage was approximately 12,000.

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

The upper deck portion of the 5th wheel frame has been moving independently of the walls which is commonly referred to as "frame flex" or "frame failure", as evidenced by the following: a gap between the wall and floor in the bedroom above the upper deck, pin box receding into the trailer, loose, bent, and missing lag bolts which connect the upper deck to the frame, irregular slide operation in the bedroom above the upper deck, man doors in the trailer being out of square, cargo doors opening during travel, separation of the seam between the filon and "nose", squeaky flooring in the bedroom above the upper deck. The manufacturer has offered to transport the trailer to their manufacturing facility and perform what they are calling a "super" inspection if we agree to sign a release and non-disclosure agreement. The structural components of the trailer are covered by a 5 year warranty which should not require a release and NDA. The trailer is not safe and would be irresponsible to use in its current condition. The "super inspection" repair scope is vague, and the required legal agreement should not be required because the trailer is within the warranty period. The trailer spent almost 10 months at an authorized repair facility. The work done at the repair facility did not resolve or fully and correctly address the frame related issues. The repair facility has in its possession approx 400 pictures of the work performed on our trailer which they will not release to us. The work orders associated with the work done during the 10 months that the trailer was in the repair facility are vague and do not detail what was or was not done.

STRUCTURE

The upper deck portion of the 5th wheel frame has been moving independently of the walls which is commonly referred to as "frame flex" or "frame failure", as evidenced by the following: a gap between the wall and floor in the bedroom above the upper deck, pin box receding into the trailer, loose, bent, and missing lag bolts which connect the upper deck to the frame, irregular slide operation in the bedroom above the upper deck, man doors in the trailer being out of square, cargo doors opening during travel, separation of the seam between the filon and "nose", squeaky flooring in the bedroom above the upper deck. The manufacturer has offered to transport the trailer to their manufacturing facility and perform what they are calling a "super" inspection if we agree to sign a release and non-disclosure agreement. The structural components of the trailer are covered by a 5 year warranty which should not require a release and NDA. The trailer is not safe and would be irresponsible to use in its current condition. The "super inspection" repair scope is vague, and the required legal agreement should not be required because the trailer is within the warranty period. The trailer spent almost 10 months at an authorized repair facility. The work done at the repair facility did not resolve or fully and correctly address the frame related issues. The repair facility has in its possession approx 400 pictures of the work performed on our trailer which they will not release to us. The work orders associated with the work done during the 10 months that the trailer was in the repair facility are vague and do not detail what was or was not done.

UNKNOWN OR OTHER

The upper deck portion of the 5th wheel frame has been moving independently of the walls which is commonly referred to as "frame flex" or "frame failure", as evidenced by the following: a gap between the wall and floor in the bedroom above the upper deck, pin box receding into the trailer, loose, bent, and missing lag bolts which connect the upper deck to the frame, irregular slide operation in the bedroom above the upper deck, man doors in the trailer being out of square, cargo doors opening during travel, separation of the seam between the filon and "nose", squeaky flooring in the bedroom above the upper deck. The manufacturer has offered to transport the trailer to their manufacturing facility and perform what they are calling a "super" inspection if we agree to sign a release and non-disclosure agreement. The structural components of the trailer are covered by a 5 year warranty which should not require a release and NDA. The trailer is not safe and would be irresponsible to use in its current condition. The "super inspection" repair scope is vague, and the required legal agreement should not be required because the trailer is within the warranty period. The trailer spent almost 10 months at an authorized repair facility. The work done at the repair facility did not resolve or fully and correctly address the frame related issues. The repair facility has in its possession approx 400 pictures of the work performed on our trailer which they will not release to us. The work orders associated with the work done during the 10 months that the trailer was in the repair facility are vague and do not detail what was or was not done.

ELECTRICAL SYSTEM

There is a serious electrical issue with the Grand Design Momentum 397ths. There are twenty-three electric outlets throughout the RV. Two are located outside. Two more are dedicated to microwave and electric fireplace. The two for microwave and fireplace are on their own breakers. All other twenty-one outlets are on just ONE 15 amp breaker. Typically there is a maximum of eight outlets per 15 amp breaker or a maximum of 10 amps on one breaker to avoid tripping the breaker. The outlet located on the side of the bathroom vanity under the sink in bathroom located in garage is not a GFCI although labeled as such. There are two GFCI outlets located in the front bathroom and the outlet beside the stove. In April of 2024 Grand Design took the RV from OH to Elkhart IN for repairs and address service bulletins for frame failure. I reported the issue at that time. I was informed the wiring of the outlets are wired according to specs and therefore no changes could be made. There is room for another breaker in the breaker box. We have been living in our RV full time and the breaker has tripped no less than six times per week. This constant overload is only leading to a fire hazards. This is yet another issue and example of potentially life threatening the RV industries refuse to make right.

STRUCTURE:BODY

We were driving through a mountain range and the trailer brakes went out on Trailer. Had to us exhaust brake to slow trailer down and stop. We could have crashed putting my family of 4 at high risk as well as others on the road. This was an extremely scary trip with no trailer braking. Our inverter and battery switch caught fire during a camping trip 8/12/24. My family was put in harm's way with the possibility of the trailer going up in flames! Called Grand Design. They immediately made a ticket for a technician to come replace inverter and other wiring. Grand Design told us we were NOT to use our trailer until all fixed. Grand Design flew a technician out 8/20/24 to replace inverter. Technician held up the inverter to us, it was melted. He said this was completely Grand Design's fault. Also was told by technician to take trailer in for frame flex issues as well from recall by Grand Design. The frame flex was real. We had issues with our slides as well as the body looking crooked on the frame. The RV service center Grand Design sent us to found that there were ZERO lag bolts installed holding the body on the frame. The front corner of trailer was leaking due to the roof failing. Grand Design called for replacement of all cabinetry in front area as well as replace entire roof. This frame flex could have had detrimental outcomes due to the frame not being bolted down. All components that failed have been fixed by a certified rv service center. We have not used the trailer as we picked it up one week ago. We are nervous to use the trailer with all the issues we had. There was no warning to any of these failures.

SUSPENSION

We were driving through a mountain range and the trailer brakes went out on Trailer. Had to us exhaust brake to slow trailer down and stop. We could have crashed putting my family of 4 at high risk as well as others on the road. This was an extremely scary trip with no trailer braking. Our inverter and battery switch caught fire during a camping trip 8/12/24. My family was put in harm's way with the possibility of the trailer going up in flames! Called Grand Design. They immediately made a ticket for a technician to come replace inverter and other wiring. Grand Design told us we were NOT to use our trailer until all fixed. Grand Design flew a technician out 8/20/24 to replace inverter. Technician held up the inverter to us, it was melted. He said this was completely Grand Design's fault. Also was told by technician to take trailer in for frame flex issues as well from recall by Grand Design. The frame flex was real. We had issues with our slides as well as the body looking crooked on the frame. The RV service center Grand Design sent us to found that there were ZERO lag bolts installed holding the body on the frame. The front corner of trailer was leaking due to the roof failing. Grand Design called for replacement of all cabinetry in front area as well as replace entire roof. This frame flex could have had detrimental outcomes due to the frame not being bolted down. All components that failed have been fixed by a certified rv service center. We have not used the trailer as we picked it up one week ago. We are nervous to use the trailer with all the issues we had. There was no warning to any of these failures.

ELECTRICAL SYSTEM

We were driving through a mountain range and the trailer brakes went out on Trailer. Had to us exhaust brake to slow trailer down and stop. We could have crashed putting my family of 4 at high risk as well as others on the road. This was an extremely scary trip with no trailer braking. Our inverter and battery switch caught fire during a camping trip 8/12/24. My family was put in harm's way with the possibility of the trailer going up in flames! Called Grand Design. They immediately made a ticket for a technician to come replace inverter and other wiring. Grand Design told us we were NOT to use our trailer until all fixed. Grand Design flew a technician out 8/20/24 to replace inverter. Technician held up the inverter to us, it was melted. He said this was completely Grand Design's fault. Also was told by technician to take trailer in for frame flex issues as well from recall by Grand Design. The frame flex was real. We had issues with our slides as well as the body looking crooked on the frame. The RV service center Grand Design sent us to found that there were ZERO lag bolts installed holding the body on the frame. The front corner of trailer was leaking due to the roof failing. Grand Design called for replacement of all cabinetry in front area as well as replace entire roof. This frame flex could have had detrimental outcomes due to the frame not being bolted down. All components that failed have been fixed by a certified rv service center. We have not used the trailer as we picked it up one week ago. We are nervous to use the trailer with all the issues we had. There was no warning to any of these failures.

ELECTRICAL SYSTEM

We are showing many signs of excessive frame flex/failure in our 2023 Grand Design Momentum 397THS. Our baggage/storage doors do not properly fit nor lock. The RV was in the shop from Jan-May 2023 to address this. Had the doors replaced and resealed. They still are not flush with the RV, still barely latch, and have popped open while driving. While in the shop, they addressed but "could not duplicate" the underbelly continuously filling with water when it rains. Excessive amounts of water that saturate all of the insulation-- causing us to drive with extra weight until we can stop and replace it all. Not sure where the water even comes from. Our filon around the hitch is seperating. Our pinch molding on both sides completely falls out. The screws holding front cap to roof popped out, sealant broken. There is wall separation in the lower deck. This causes excess rubbing of the walls, popping trim pieces off, and dust left after any movement of the RV. There is loud creaking and popping as we lift our RV off of our truck. The lag bolts are unscrewing themselves from the frame in the upper deck. Slide in the upper deck is digging into the flooring, leaving indentations, while in transit. Floor creaking in upper deck. Our electrical wiring for our running lights/turn signals/brake lights, as well as our leveling system wires were zip tied to the spindle of our slide. This caused the wires to wrap around over and over and slice themselves apart. In turn causing ALL of those systems to fail-- no running lights, no turn signals, no brake lights, and our jacks would not go down.