Excessive Frame Flex / Failure
Symptoms List
This list is more accurately updated (4/5/25) using Microsoft Co-pilot (A.I.). Definitely missed a few things in the previous rendition.
Have you been through the symptoms list yet to verify ALL possible frame failure symptoms? You will want to list out all of your possible frame failure symptoms before contacting the National Highway Traffic Safety Administration (NHTSA) to file a formal safety complaint then and only then file a manufacturer defect warranty claim with your list of frame failure symptoms with your RV manufacturer and make sure when you do, you do this through email, not phone calls. You will want a paper trail of the conversations when it comes to the RV manufacturer. Trust me, they are not to be trusted!
Note:
Measurements from the pin box alone do not verify by itself whether you have frame failure or not. Do not let a dealership or RV manufcturer try to tell you any different. Make them remove the phylon and have the welds inspected as well as cracked/broken steel tubing. Also, inspect the back of the frame near the suspension. The any frame warranty covers the entire frame not just one section of it.
Signs of RV Frame Flex or Failure:
1. Cracking: Cracks near the corners of upper deck slide openings.
2. Panel Separation: Separation of interior or exterior panels.
3. Structure Separation: Separation of structures from the wall in the upper deck.
4. Pin Box Issues: Pin box moving independently from the RV. 3/8” allowable tolerance according to RV manufacturer. This is suspect also though. Phylon is required to be removed to visually check for cracked/broken welds as well as broken steel tubing/beams.
5. Rub Marks and Bulges: Rub marks on walls near cabinets and bulging walls, especially in the front area.
6. Trim Pieces Coming Out: Trim pieces repeatedly coming out.
7. Decal Ripples and Wrinkles: Ripples or wrinkles in decals, especially at the dropdown frame site on the off-door side.
8. Screws Snapping: Screws holding trim, soap dishes, or other fixtures snapping.
9. Door Alignment Issues: Doors are misaligned, allowing water to enter.
10. Warped Cargo Doors: The front cargo door is warped and difficult to lock. Cargo and propane doors opening during transport (file NHTSA complaint)
11. Closet Door Issues: Closet doors are difficult to keep sliding smoothly or constantly getting out of alignment.
12. Bulge Across Floor: Large bulge across the floor above the rear jacks. Use a carpenter's level for bulging floors (east-west).
13. I-Beam Cracks: Cracks in the I-beam.
14. Excessive Frame Flex: Excessive frame flex acknowledged by Grand Design.
Additional Symptoms:
· Sawdust on/in Furniture: Sawdust in the nose of the RV (check inside cabinets between trips).
· Furniture Movement: Furniture rubbing walls or moving up and down or forward and back.
· Broken Furniture: Broken furniture in the nose of the RV. Cabinets falling out (critical safety issues - file NHTSA complaint)
· Lag Screws Issues: Unscrewing, loose, missing, or bent lag screws in the upper deck. 3/8" lag screws MUST be replaced with 1/2" and all holes filed with lag screws. They will come out again!
· Excessive Noise: Popping, grinding, or creaking of walls when lowering and raising the trailer on/off the truck.
· Trim Movement: Trim pieces on the front exterior move when hitched vs. unhitched (indicates frame failure).
· Pin Box Sinking: Pin box sinking into the RV upper deck when lowering onto the truck (urgent frame failure - do not tow).
· Roof Membrane Separation: Roof membrane separating at the front cap. This will cause water damage.
· Nose Cap Separation: Nose cap separating from the roof membrane (indicates frame failure).
· Stress Fractures: Stress fractures in fiberglass on the cap of the RV.
· Pinch Molding Issues: Pinch molding coming loose from the underside of the fifth wheel skin or philon.
· Screws Backing Out: Screws backing out and/or breaking on the slide in the upper deck.
· Delamination: Delamination at the bottom of the sidewalls close to the trim near the front cap. Delamination is when the outer fiberglass or gel coat layer separates from the underlying substrate (usually a combination of plywood, Styrofoam, and other materials) due to moisture intrusion, poor sealing, or structural damage.
What to Do if You Suspect a Problem:
1. Inspect Regularly: Regularly check your RV for signs of frame flex or failure.
2. File a formal complaint with NHTSA first:
3. Contact Grand Design: Discuss concerns and warranty options with Grand Design.
4. Seek Professional Advice: Consult with a qualified RV repair shop or technician.
5. Document Everything: Keep detailed records of your RV's history, issues, and communication with Grand Design or repair shops.
If you have any specific concerns or need further assistance, feel free to ask.
(info@rvadvocacy.com)
What is RV Delamination
On an RV, delamination occurs when the outer fiberglass or gel coat layer separates from the underlying substrate (usually a combination of plywood, Styrofoam, and other materials) due to moisture intrusion, poor sealing, or structural damage.
Here's a more detailed explanation:
What it is Delamination:
- Delamination is a common problem in RVs, particularly in older models, where the outer layer of fiberglass or gel coat, designed to protect against weathering, starts to separate from the inner layers of the wall or roof.
Causes:
Moisture Intrusion: Water seeping through damaged seals, cracks, or penetrations (like windows or vents) can cause delamination.
- Poor Sealing:Inadequate or deteriorated sealant on seams and edges can allow water to penetrate and cause delamination.
- Structural Damage: Impacts or dents to the underlying materials (plywood, Styrofoam) can create air pockets that cause the bonding agent to fail and separate.
- Temperature Fluctuations: Rapid and extreme temperature changes can weaken the adhesives used to bond the layers, leading to separation.
Signs of Delamination:
- Bubbles or Blisters: On the exterior walls or roof, these are a clear sign of delamination.
- Cracks: Small cracks in the outer layer can indicate the start of delamination.
- Soft or Wobbly Walls: If the walls feel soft or wobbly when pressed, it could be a sign of delamination.
Consequences:
- Water Damage: Delamination allows water to penetrate the RV's walls, which can lead to rot, mold, and further damage.
- Structural Weakness: Delaminated areas can weaken the RV's structure and compromise its ability to withstand stress. Expensive Repairs: Fixing delamination can be costly, especially if the damage is extensive.
Prevention:
Regular Inspection and Maintenance: Inspect seams, seals, and penetrations regularly and reseal any damaged areas promptly.
- Proper Sealing: Use high-quality, weather-resistant sealant and ensure all seams are properly sealed.
- Promptly Address Damage: Address any damage to the RV's exterior promptly to prevent it from worsening.
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· Seek Professional Advice:
Consult with a qualified RV repair shop or technician for an inspection and diagnosis.
· Document Everything:
Keep detailed records of your RV's history, any issues you encounter, and any communication with RV manufacturer or repair shops.