NHTSA Complaint #11649791 — 2022 GRAND DESIGN REFLECTION

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.