2017 Grand Design Reflection

INTERMITTENT BRAKES (LOST BRAKES) ON FIFTH WHEEL DUE TO THE USE OF UNDERSIZE WIRE AND OVERUSE OF SCOTCHLOK GUILLOTINE CONNECTORS. EACH BRAKE HAS A MAXIMUM CURRENT DRAW OF 4AMPS. 4X4 = 16 AMP POSSIBLE DRAW ON 14 AWG WIRE AT APPROXIMATELY 60+ FOOT LOOP ROUND TRIP FROM PIN BOX TO BRAKES BACK TO PIN BOX. THIS IS AN EXTREMELY DANGEROUS SITUATION. THE BRAKE WIRING IS SUBSTANDARD IN EVERY CONCEIVABLE WAY. SHOULD BE AT LEAST CONNECTED 10AWG USING CRIMPED BUTT SPLICES AND CIRCLE CONNECTORS. IT WOULD ALSO HELP TO HAVE A GROUND BOND AT THE AXLE TO REDUCE THE LOOP BY 50%. SOMEDAY SOMEONE WILL DIE (PROBABLY HAVE ALREADY) BECAUSE OF CHEAP UNDERSIZED WIRE WITH CHEAP GUILLOTINE CONNECTORS EVERYWHERE. FOR LIGHTS OK FOR BRAKES? NEVER!*DT*JB

TL* THE CONTACT OWNS A 2017 GRAND DESIGN REFLECTION FIFTH WHEEL TRAILER EQUIPPED WITH WESTLAKE SUPER ST TIRES, SIZE: ST225/75/R15, DOT NUMBER: JULT1CM4016. THE CONTACT NOTICED A BULGE ON THE SIDEWALL OF THE FRONT PASSENGER TIRE UPON INSPECTION AT A REST STOP. THE CONTACT STATED THAT WHILE DRIVING UP A HILL AT 45 MPH, THE FRONT PASSENGER'S SIDE TIRE EXPERIENCED A BLOWOUT. THE CONTACT REPLACED THE WHEEL WITH THE SPARE TIRE ON THE TRAILER AND DROVE TO A TIRE SHOP. HE WAS INFORMED BY THE MECHANIC THAT THE BLOWOUT WAS CAUSED BY INTERNAL TREAD SEPARATION. THE TIRE WAS REPLACED AND THE FAILURE RECURRED ON THE DRIVER'S SIDE FRONT TIRE WHILE DRIVING 60 MPH. THE CONTACT PLACED THE SPARE TIRE ON THE TRAILER AND PURCHASED NEW SET OF TIRES. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE CONTACT WAS INFORMED TO SUBMIT A CLAIM FOR REIMBURSEMENT. THE APPROXIMATE TIRE AND VEHICLE FAILURE MILEAGE WAS 5,000.*DT*JB

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.

THE RIGHT REAR LEAF SPRING HANGER FOR THE REAR AXLE BROKE OFF FROM THE TRAILER FRAME, THIS HAPPENED WHEN VEHICLE WAS IN MOTION ON THE HIGHWAY. NOTICED REAR AXLE OUT OF PLACE WHEN WE WERE PARKED IN OUR DRIVEWAY UPON FURTHER INSPECTION THAT IS WHEN WE NOTICED THE RIGHT REAR HANGER BROKEN COMPLETELY OUT OF FRAME AND THE LEFT REAR HANGER CRACKED.

TWO SEPARATE ISSUES: 1. LIPPERT WHEEL BEARINGS LEAKED GREASE ALL OVER THE DRUM BRAKES WITH LESS THAN 4000 MILES. LIPPERT REFUSED TO PAY FOR REPAIRS BECAUSE IT HAS BEEN MORE THAN ONE YEAR. 2. WITH BRAND NEW BRAKES PROPERLY ADJUSTED, BRAKES ARE STILL VERY WEAK. APPLYING 12 VOLTS FROM BRAKE CONTROLLER RESULTS IN MINIMAL BRAKING. SUSPECT UNDERSIZED FINAL WIRING TO BRAKES (20 GAUGE). BRAKES HAVE BEEN UNDERPERFORMING SINCE DAY 1. *DT*JB*DT*JB

MY COMPLAINT IS FOR WHEEL BEARINGS. I'VE CONTACTED BOTH SELLER BYOUNG RV IN PORTLAND OREGON (XXXX) AND MANUFACTURE GRAND DESIGN RV (XXXX). MY TRAILER HAS BEEN HAVING ISSUES WITH EXCESSIVE RESIDUE BUILD UP ON WHEELS. ANOTHER REFLECTION OWNER TOLD ME HIS TRAILER WAS DOING SAME THING. THE DEALER WHERE HE PURCHASED TRAILER (BLUE DOG RV IN REDMOND OREGON) TOLD HIM REFLECTIONS WITH THIS PROBLEM IS BECAUSE THE WRONG SIZE BEARINGS WERE USED. MY TRAILER NOW HAS 5800 MILES. I'VE SENT ON PICTURES TO BOTH DEALER AND MANUFACTURE. MARK ARPIN TOLD ME NO ISSUES OF IMPROPER BEARING EXISTS. IF SO WHY WOULD BLUE DOG SAY DIFFERENT? COULD THIS TURN INTO A HAZARD OR SAFETY CONCERN? THANK YOU FOR YOUR TIME. (XXXXX) PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

THE BRAKES, SEALS AND BEARINGS ON MY 5TH WHEEL TRAVEL TRAILER WILL HAVE TO BE REPLACED FOR THE THIRD TIME DUE TO THE SEALS LEAKING GREASE ONTO THE BRAKES. ALL FOUR BACKING PLATES, THE FRONT TWO HUBS AND ALL FOUR GREASE SEALS AND BEARINGS WERE REPLACED ON OUR FIRST TRIP AFTER TAKING POSSESSION OF THE FIFTH WHEEL IN MAY 2017. THIS WAS DONE AT A CAMPING WORLD DEALERSHIP IN NORTH CAROLINA AND RESULTED IN BEING WITHOUT THE USE OF OUR TRAILER FROM MAY 18 ' 23. ON OUR SECOND TRIP, STARTING ON JULY 9, 2017, THE BRAKES AGAIN BEGAN PERFORMING POORLY. RAY DUFFY, OF GRAND DESIGN, ARRANGED TO HAVE THEM INSPECTED IN WEST YELLOWSTONE, MONTANA ON JULY 14, 2017 AT JAKE'S AUTOMOTIVE. HE PRE-SHIPPED REPLACEMENT PARTS IN ANTICIPATION OF BAD SEALS. THE TECHNICIAN AT JAKE'S AUTOMOTIVE FOUND GREASE CONTAMINATION ON THE RIGHT FRONT, RIGHT REAR AND LEFT REAR BRAKES. HE ALSO FOUND THAT THOSE SEALS AND BEARINGS HAD SEPARATED FROM THE HUBS AND REMAINED ON THE SPINDLE WHEN THE HUBS WERE REMOVED. THE RECEIPT STATES, 'HAD TO REPLACE 3 OF FOUR BACKING PLATES AND HARDWARE DUE TO WHEEL SEALS BLOWING OUT.' THE FOURTH WHEEL, THE LEFT FRONT, WAS NOT REMOVED OR INSPECTED BY THE REPAIR FACILITY SINCE THEY DID NOT HAVE REPLACEMENT PARTS AVAILABLE AND THEY WERE CONCERNED THAT REMOVAL OF THE WHEEL COULD DAMAGE THE GREASE SEAL. I REMOVED ALL FOUR HUBS TODAY. THE INTERIORS OF THE TWO LEFT HUBS WERE COMPLETELY COATED WITH GREASE. THE LEFT FRONT WAS WORSE THAN THE LEFT REAR. THE TWO RIGHT HUBS DID NOT HAVE AS MUCH GREASE ON THEM AND WERE EVIDENTLY DOING THE MAJORITY OF THE BRAKING. THE INSIDE OF BOTH HUBS WERE PRETTY SEVERELY SCORED BY THE MAGNETS AND NEED TO BE REPLACED. ALL FOUR GREASE SEALS AND THE INNER BEARINGS STAYED ON THE SPINDLES WHEN THE HUBS WERE REMOVED. SINCE THE SEALS ARE SUPPOSED TO BE PRESSED IN, I FOUND THEIR REMAINING ON THE SPINDLES PROBLEMATIC.

BRAKES WERE NOT WORKING VERY WELL, WITH THE TRAILER BRAKE CONTROLLER GAIN IN MY TRUCK SET AT 10.0 (FULL ON). PROBLEM WAS CAUSED BY LEAKING AXLE SEALS ON THE PASSENGER SIDE OF THE VEHICLE WHICH RESULTED IN THE BRAKE SHOES AND DRUMS BEING COATED WITH AXLE GREASE. ALL FOUR BRAKE ASSEMBLIES AND AXLE SEALS WERE REPLACED BY THE DEALER UNDER WARRANTY.