Forum Discussion

Espee's avatar
Espee
Explorer
Jan 11, 2014

Diagnosing Lippert Frame issue with my Cougar

Read lots of posts about similar issue with the front cross member splitting on my frame. I have the cabinets getting torn apart similar to pics I have seen in these threads, so suspecting the same cross member issue as others here have had to deal with. After removing the lower shroud under the bedroom to inspect the framing, I am unable to find any broken welds or splitting of the beams / cross members, but something has to be causing the damage to my closets... if the beam was splitting, wouldn't I be able to view it from below?
Is my frame just flexing more and more now days, and it is just a matter of time until it finally splits and cracks thereby tearing apart the welds etc? If I reinforce the front cross member now, will it solve my cabinet issue? Next step is to pull up the flooring to inspect from above, but wanted some feedback from others before I go to all the trouble. Any feedback would be appreciated.
Here are a few pics of the current damage that I have tried to repair, but keeps getting ripped apart each time. It seems it is getting worse and I see at least an inch of movement between the hitch and the front cap on bouncy roads...





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  • Allworth's avatar
    Allworth
    Explorer II
    Jan 12, 2014
    And why does it matter if the frame is Lippert or something else?
  • C_Schomer's avatar
    C_Schomer
    Explorer
    Jan 12, 2014
    I agree on frame flexing and possibly breakage. I had a 5er that wasn't as bad as yours but it was totally from flexing and no breaks or cracks in the frame. It wasn't covered under the bedroom so I could see all of the frame and it was fine - just not strong enough. Does yours have an extended pin box? All of my 5ers have had them and I switched all of them to standard length boxes. I can do that cuz I have a LB truck and what a difference in flexing that makes! Taking off 10" cuts it in half. I traded my long box for a short box with a friend one of the times but otherwise I cut mine apart and move the pin back and weld it back together. Craig
  • Dayle1's avatar
    Dayle1
    Explorer II
    Jan 12, 2014
    The plywood floor sits on the steel frame and moves as the frame flexes. If the front crossmember is failing, then the floor directly above the pin box will have the most movement. Also, generally the interior skin of the front wall sits on top of the floor (or is attached to it) and so majority of wall damage will also be above the pin box.

    However, the sidewalls don't sit on the outside frame rails but usually have horizontal bolts thru the aluminum frame and then thru the box steel frame. So, they are about 4 inches long and they can become loose and elongate the holes in the aluminum framing and allowing the sidewalls to flex too much. If the damage you are seeing is worse at the side walls, then this is the likely problem. Some brands insert wood blocks into the hollow aluminum tubing to minimize this issue. You will need to drop the skin under the bedroom floor and remove the front cap to gain access to the open end of the aluminum frame. Custom steel inserts would be better than soft wood. If new bolts are needed, then the sidewall skin will need to be pulled off as well.
  • R-D's avatar
    R-D
    Explorer
    Jan 12, 2014
    We have an 09 Keystone Everest with the same issue, your pictures of the closet looked just like our pictures. We had obvious problems on the outside also. Lippert welder had to make some repairs before it could even be transported to Keystone factory (Home of the Cougar) in Pendleton, OR. It has been there 2 times now. We are keeping our fingers crossed at this point. Most dealers say they can fix the issue but we found none that could. The gang in Pendleton are excellent and know what they are doing and make many of these repairs. Maybe you could make a trip out of it. The Columbia river gorge area is beautiful. Good luck. It can be fixed by the factory.
  • wrgrs50s's avatar
    wrgrs50s
    Explorer
    Jan 12, 2014
    I had a frame flex issue with my Heartland Sundance, which also uses Lippert frames. The factory had to seperate the front cap and peel the outside skin back about 3ft on each side to expose the aluminum frame inside the walls. They found and repaired broken welds there, and braced up the steel frame with large gussets.
    Mine was also showing flexing at the pin while towing. I could not see any movement inside like your pictures show but the trim on the outside of the trailer was seperating and closing when hitching and unhitching.
  • ronniedean1234's avatar
    ronniedean1234
    Explorer
    Jan 11, 2014
    Looks like frame flex to me, our Montana has had it happen twice and repaired by a dealer the first time then by Keystone the second, good luck with repairs...
  • Old-Biscuit's avatar
    Old-Biscuit
    Explorer III
    Jan 11, 2014
    With the front overhang panel removed (the panel that covers bottom of overhang/around pin box) hitch up trailer to truck.

    Then while raising front landing gear watch for excessive movement of outside walls as weight is transferred from landing gears to truck.

    I bet the outside wall attachments have broken and and walls are moving.
  • guamuchil31's avatar
    guamuchil31
    Explorer
    Jan 11, 2014
    do you have a filon cap or hard fiberglass cap.does it have pinbox underbelly?

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