2018 Keystone Passport 2810bh top bunk falling off wall

[Booch]

Noticed some sagging in the top bunk when I went to check on the RV a few weeks ago. Pulled the mattress and sheet off and wow, it's basically falling off the outside wall. Lots of discoloration, and split wood, and looks like water damage.

The window was shut, it's actually never been opened that I know of, as my family is all about the A/C. And even with the 300lb limit, there hasn't been anyone up there over 200lbs, because I don't think it'd hold 200lbs by the looks of the construction.

There's a 3 year structural warranty, but it's being called damage and not covered. Of course it's damage, but I don't really think it's my fault.

Anyone else had to fight this battle with the dealer/manufacturer?

[flybouy]

Water damage is just that "damage" and not a structural defect. You need to find the leak (most likely the roof) and seal it properly and then repair the damage.

[Booch]

Originally Posted by flybouy

Water damage is just that "damage" and not a structural defect. You need to find the leak (most likely the roof) and seal it properly and then repair the damage.

So the leak is not considered a structural defect on a 2 year old RV?

[travelin texans]

Originally Posted by Booch

So the leak is not considered a structural defect on a 2 year old RV?

Keystone & your dealer will probably, actually definitely, tell you it was lack of roof maintenance by you or whomever does your periodic maintenance thereby denying all claims. If you pay someone to do your roof maintenance then you need to contact them for roof repairs & water damage.

[flybouy]

Originally Posted by Booch

So the leak is not considered a structural defect on a 2 year old RV?

No it is not. Read the warranty that came with your unit or go to Keystone web site and read it. There you will find the maintenance required by the owner for the roof. If the factory failed to staple the roof on and it fell in and leaked then you may have a claim.

Claiming a structural defect for a leaking roof that was not maintained would be like expecting Ford, GM, or FCM to replace your rotors on your truck under warranty when you let the brakes wear out and tear up the rotors.

[Logan X]

I think Keystone says the roof needs to be inspected and maintained every 90 days...

If there is also a window right there, I would take a hard look at the seal around the window.

[Booch]

Originally Posted by Logan X

I think Keystone says the roof needs to be inspected and maintained every 90 days...

I hope you are kidding, but based on my experience with this one (which is my 3rd TT), that might be true. I had a list of 28 things for them to fix at my 1 year check-in. 3 of the 4 compartments leaked. I'm barely into year 2 now, and do inspect it regularly and nothing (especially seams and joints) looks in need of repair.

But, I guess it is what it is. That 3yr structural warranty isn't much beyond marketing. So, onto the fix. It's a wood bed frame, no big deal. But, what's in the walls? Are they wood studs that I'll find with a stud-finder? Metal? Any advice so I don't make things worse would be appreciated.

[Booch]

Well after checking my roof seams and caulk, checking all the 'every 90 days stuff' the manual says, rebuilding the bunk, I found out where the leaks are. They are around the windows. None of them have caulk. We had water on the floor below every window after a downpour this weekend.

Doors have caulk, compartment doors have caulk, vents have caulk, lights have caulk, connection boxes have caulk.. why do the windows not have caulk? Did they forget this (wouldn't surprise me), or is it by design?

[travelin texans]

Most all you've mentioned should have butyl tape, looks like putty, as a sealant under the flanges. Because there's not a thick bead of caulk visible around each doesn't mean they're not sealed. Not saying the factory didn't/couldn't make a mistake, but further inspection is needed before saying they ARE NOT sealed & if not remove the item & use the butyl tape, don't smear silicone all around the place.

[JRTJH]

Brooch,

If your windows are "frameless" there is a "closed cell foam tape" applied to the windows by the window manufacturer and no further seal is applied at the factory. If your windows have frames on the outside flange, then the factory applies a layer of clay or butyl putty tape (about 1/8" thick and 3/4" wide) around the perimeter before installing the windows.

On some trailer brands (not every brand produced by Keystone) there is also a ProFlex or ProSeal bead applied at the top of each window frame. That does not occur with every trailer brand, likely only the more expensive brands, but I've seen it on Hideouts as well as on Alpines, so I don't know what the "factory rules" are concerning which trailers get extra sealant above the windows.

The "missing sealant on your windows" may not be a defect, rather a "design feature" of the type window or a assembly line process, not a "missed step"...

Road vibrations can loosen the flange screws, allowing the window to shift in the opening, causing a leak. If you look at the inside perimeter of your windows, you'll find a black aluminum flange with multiple screws in it. Check them for looseness and if loose, retighten the screws. Take care to tighten them in a "opposite side stepped process" rather than just going around the perimeter with a screwdriver. If you don't tighten them equally and in a stepped sequence, you may deform the ring and permanently damage the window by twisting it out of shape.....