NHTSA Complaint #11642276 — 2022 KEYSTONE MONTANA

The model is a High County 385 BR and a crack appeared below the front bedroom slide and the slide stopped working correctly. I took the unit to Blue Compass in Katy, Texas and they discussed the issue with Keystone which resulted in the completion of what they called a flex test, basically they measure the distance between a fixed point in the hitch and the lower frame with the unit on ground on its jacks and then lift it on the king pin and make the same measurement, which I'm told needs to be 1/2" max, mine was over 1". So they took body work off to allow inspection of the main structural frame ( supplied by LCi) and aluminum framing and found broken aluminum framing welds, what appears to be cracked structural welds and a cut out on the structural frame which doesn't appear to meet their specification. The quality of the welding is poor at best with lots of undercut, blow holes, lack of fusion, lack of fill, etc, I'm assuming Keystone and LCi operate under self inspection. Keystone initially provided a repair procedure which they told me was NSTB approved, but seems like we have gone beyond this position with the welding to be inspected by LCi on the 10th March. As I've read may cases online about the subject of RV Flex, and Keystone providing a repair procedure which they stated was NSTB approved I'm writing this note to yourselves as I'm thinking the extent of the problem may not have been provided to NSTB when the procedure KSB-210122 V2 was provided to yourselves. I'm writing this note as I'd hate to see one of these units fail on the highway due to the issues I see in the frame of my unit. I can provide pictures on the welds, etc if required, you can email me at [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)