NHTSA Complaint #11362230 — 2017 GRAND DESIGN REFLECTION

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.