Fleetwood-Excursion RV Exposed: Water Leaks, Slide-Out Failures, DEF Derates & Service Delays
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Fleetwood-Excursion
Location: 1031 US-224 E, Decatur, IN 46733
Contact Info:
• owners@fleetwoodrv.com
• Sales 800-322-8216
• Service 877-466-6226
Official Report ID: 1183
Introduction: What Shoppers Should Know About the Fleetwood Excursion
AI-powered research tools have systematically collected and analyzed public information to produce this report. The Fleetwood Excursion is a compact Class A diesel pusher motorhome historically positioned as an “entry-level diesel” within Fleetwood’s lineup (a REV Group brand). Built on Freightliner diesel chassis across multiple model years, the Excursion attracted buyers with manageable length, full-body paint, and big-coach amenities in a smaller footprint. Its overall reputation, however, is mixed: owners praise the floorplans and drivability, but recurring reports document quality-control issues, water intrusion, slide-out problems, emissions-related engine derates, and long waits for warranty and parts. This report distills the most common, serious, and costly patterns of problems so you can assess risk before you buy.
Independent Owner Communities and Research Links
Before deep-diving, we strongly recommend you gather first-hand, unfiltered owner feedback in communities and searchable public records. Start here:
- YouTube owner videos on Fleetwood Excursion Problems (search for multi-year patterns and repair diaries)
- Google search: Fleetwood Excursion Problems (scan forums, blogs, dealer responses)
- BBB search: Fleetwood Excursion (look for warranty and service-delay complaints)
- Reddit r/rvs: Fleetwood Excursion Problems • r/RVLiving • r/GoRVing
- NHTSA recall search: Fleetwood Excursion (vehicle safety recalls, defects, complaints)
- RVInsider owner reviews: Fleetwood Excursion Problems
- Good Sam Community: Fleetwood Excursion Problems
- RVForums.com and RVForum.net (use each site’s search for “Fleetwood Excursion”)
- RVUSA Forums (search “Fleetwood Excursion Problems” in the header)
- Find Fleetwood Excursion owner groups on Facebook (Google search) for unfiltered, model-specific owner threads
- PissedConsumer (open site and search “Fleetwood Excursion” and “Fleetwood RV” manually)
For consumer watchdog commentary on systemic RV industry issues, check out Liz Amazing’s channel and search within her videos for the exact brand/model you’re considering. Her buyer warnings and maintenance checklists are frequently cited by owners.
Have you owned an Excursion? Add your story for other shoppers.
Arrange a Third-Party RV Inspection Before You Buy
One of the strongest patterns in owner complaints is discovering defects only after signing—then waiting weeks or months while the coach sits at the dealer for parts and authorization. Your best leverage is a pre-delivery inspection (PDI) performed by an independent, certified RV inspector—before you accept the unit. If issues are found after you take possession, many dealers will place you behind sold units in their service queue.
- Schedule an inspector who will test water intrusion, delamination, slide alignment, roof integrity, chassis electronics, generator load, and all appliances.
- Ask for moisture readings, thermal imaging of slide/roof areas, and a documented road test.
- Negotiate repair commitments and holdbacks based on the inspection results; do not sign until items are corrected in writing.
Find inspectors: RV Inspectors near me. If the seller resists, consider that a red flag. Some buyers report cancelled trips and lost deposits because their coach ended up stuck at the dealer for months awaiting parts.
Key Problem Patterns Reported by Fleetwood Excursion Owners
Water Intrusion, Roof Seams, and Delamination
(Serious Concern)
Across model years, owners repeatedly document roof and wall water intrusion leading to soft floors, musty odors, and costly fiberglass delamination. Common entry points include front and rear cap seams, roof penetrations (vents, antennas), slide-toppers, window frames, and compromised butyl tape around trim. Once moisture infiltrates, it can separate lauan substrate from fiberglass skin, causing visible bubbles and structural degradation.
- Red flags to inspect: ripple or bubbling under full-body paint, soft or stained ceiling panels, swollen cabinetry near exterior walls, and cracked sealant around cap joints.
- Owners report sealant failures within a year on some units, requiring aggressive re-caulking and proactive roof reseal schedules.
Research examples: Fleetwood Excursion Water Damage, YouTube: Fleetwood Excursion leaks, and RVInsider complaint threads.
Want other owners to benefit? Share what leak fixes worked for you.
Slide-Out System Failures and Alignment
(Serious Concern)
Slide-outs are a frequent pain point. Reports include Schwintek rail failures, motors and gearboxes burning out, slide floors rotting from water ingress, and full-wall slides binding or racking. Some owners describe being unable to extend or retract a slide, trapping interior access or forcing emergency manual retraction. Misalignment can chew seals, invite water intrusion, and warp cabinetry.
- Symptoms: squealing or grinding noises, uneven gaps, slide top rubbing the wall, repeated motor “current limit” errors, or gear teeth shavings on the floor.
- Consequences: interior damage and lost travel plans while waiting for proprietary parts and authorized techs.
Verify patterns via YouTube: Fleetwood Excursion Slide Problems, forum threads on Good Sam: Slide Issues, and Reddit: Slide Problems.
Emissions Equipment and DEF Head Failures (Freightliner/Cummins)
(Serious Concern)
While not unique to Fleetwood, Excursions on Freightliner chassis with Cummins engines are not immune to DEF (diesel exhaust fluid) head and sensor failures. A failed DEF head can trigger a “5 mph” derate that strands owners. Multiple-year industry shortages of updated DEF sensors exacerbated downtime. Owners also cite check-engine lights, SCR/NOx efficiency codes, and dealer ping-pong between chassis and coach warranty lines.
- Impact: towing costs, hotel stays, and weeks waiting on emissions parts; some owners carry spare DEF components when possible.
- Mitigation: verify calibration updates, ask about DEF head part revisions, and scan for active/inactive fault codes at PDI.
Resources: NHTSA recall/complaint search, and owner threads via Google: Excursion DEF Head Problems and Reddit: DEF Problems.
Electrical Gremlins and Multiplex Control Issues
(Moderate Concern)
Owners report intermittent lighting, GFCI trips, and multiplex control module glitches that require resets or component replacement (e.g., Intellitec or similar systems). Battery control centers, ground faults, and poorly crimped connections are recurrent themes in reviews. Symptoms can mimic inverter/charger problems and leave critical circuits inoperative.
- Check: proper battery cabling gauge and torque, clean grounds to the frame, and verify all 120V outlets under load with space heaters.
- Ask: for module software versions, wiring diagrams, and location of reset points before leaving the lot.
Owner discussions: Google: Excursion Electrical Problems and Good Sam: Electrical threads.
Leveling Jacks and Hydraulic Leaks
(Moderate Concern)
Hydraulic jack systems (variously HWH or Power Gear depending on year) are cited for slow or non-retracting jacks, fluid leaks, and sensor faults. Owners sometimes carry wooden blocks because jacks won’t fully extend or retract. If seals fail, hydraulic fluid can mist underbody components and damage bushings.
- Inspection tip: extend jacks fully, listen for pump strain, check for damp cylinders, and verify auto-level accuracy on slightly sloped ground.
Research threads: YouTube: Leveling Jacks Problems, Google: Hydraulic Leak.
Exterior Awnings, Roof Sealant, and Paint Checking
(Moderate Concern)
Carefree/Girard awnings can suffer from mounting bracket loosening, wind-sensor failures, and fabric tearing at stitch lines. On some dark full-body paint schemes, owners report “checking” or micro-cracking in gelcoat in hot climates. Sealant shrinkage around caps and rails can open pathways for water ingress if not maintained.
- Look for: missing awning fasteners, rust streaks near brackets (sign of moisture), fine spider-web cracking on upper caps.
See also: Awning Problems and Roof Leak videos.
HVAC and Generator Underperformance
(Moderate Concern)
Owners describe roof A/C units struggling in hot weather and Onan diesel/LP generators that intermittently shut down under load or fuel-starve on steep grades if pickup tubes are mis-set. Ducting leaks and poor plenum sealing can further rob A/C efficiency.
- Checklist: perform a 30–60 minute generator load test (A/Cs and microwave simultaneously), and use a thermometer at supply/return vents for delta-T performance.
Explore threads: Good Sam: Excursion AC Problems and Onan Generator Problems.
Refrigerator Recalls and LP System Concerns
(Serious Concern)
Many diesel pushers of the Excursion’s era shipped with Norcold or Dometic absorption refrigerators covered by multiple safety recalls related to fire risks. Separate recall bulletins in the RV industry have addressed LP gas line routing and chafe risks, including on some REV Group products. Owners should verify recall completion and inspect for proper LP line support and heat shielding around exhaust paths.
- Action: run the VIN through the NHTSA recall database and confirm recall labels and service invoices are present in your coach records.
More: Norcold recall discussions and LP Gas Issues.
Weight, Tires, and Handling
(Moderate Concern)
Shorter diesel pushers can be sensitive to loading. Owners report front-axle loads close to GAWR when full of passengers and fuel, resulting in harsher ride, steering wander, and blowout anxiety if tires are under-spec or under-inflated. Common upgrades include Safe-T-Plus steering stabilizers, rear trac bars, and progressive springs; however, these are band-aids if loading is improper.
- Due diligence: get four-corner weights, set tire pressures per actual load, verify DOT tire ages, and check for fender well rub marks under compression.
Owner experiences: Handling Problems and Tire Blowout threads.
Fit, Finish, and Interior Component Failures
(Moderate Concern)
Numerous 1-star reviews across platforms cite misaligned cabinet doors, failing latches, weak drawer slides, squeaks, and early delamination of countertop edges. While many items are “fixable,” they add up—especially if you’re paying diesel-pusher prices and then waiting for warranty authorization for trim components.
- Fast checks: open/close every cabinet at highway speeds (test drive), inspect hidden screws for stripping, check sofa/bed frames for looseness, and test all shades for even operation.
Find examples: Quality Issues and Owner complaints on RVInsider.
Warranty Authorization, Parts Delays, and Dealer Service Backlogs
(Serious Concern)
Among the most frustrating themes: getting warranty work scheduled and completed. Owners describe coaches sitting for weeks while dealers wait for authorization or back-ordered parts from suppliers, with the customer caught between the manufacturer, the chassis OEM, and component vendors. Some describe missed camping seasons and loan payments on sidelined coaches.
- Prevention: document everything during PDI, with photos and videos; get signed “We Owe” repair lists; and avoid taking delivery with outstanding major items.
- Escalation: if work stalls, file written complaints with the dealer GM, the brand’s customer care, and the BBB; keep written timelines.
Investigate similar cases via BBB complaint searches for Fleetwood Excursion, Google: Warranty Problems, and YouTube: Dealer Service Complaints.
Had lengthy service delays? Tell others how you handled it.
Safety and Financial Risk: What These Issues Mean for You
Mechanical and structural problems don’t just ruin vacations—they carry real safety and financial consequences:
- Safety hazards: emissions derate events can strand you in unsafe places; water leaks can drive mold growth; refrigerator/LP system recalls address documented fire risks; failing jacks can drop unexpectedly or fail to retract at departure time.
- Repair costs: slide rebuilds, delamination repairs, and electrical troubleshooting can run into thousands, and interior water damage can total a coach if ignored. Even under warranty, time lost is expensive (storage, alternate lodging, missed reservations).
- Depreciation: an Excursion with a paper trail of major repairs may be harder to sell and could appraise lower, especially if evidence of leaks or slide issues is visible upon inspection.
To reduce risk, verify open recalls are closed before purchase (use NHTSA by VIN and model), scan for diagnostic codes at a Freightliner/Cummins service center, and insist on complete service records. Also, schedule a pre-purchase inspection: Find RV inspectors near you.
Legal and Regulatory Warnings
If you encounter repeated defects, protracted warranty delays, or safety issues, consider the following avenues and rights:
- Magnuson-Moss Warranty Act (federal): requires manufacturers to honor written warranties and prohibits deceptive warranty terms. Keep meticulous records of all repair attempts and communications.
- State “lemon” laws: Many states extend lemon protections to motorhomes (definitions vary; often chassis vs. “house” portions are treated differently). Research your state’s thresholds for days out of service and number of repair attempts.
- NHTSA complaints: If you experience a safety defect (e.g., emissions derate causing hazard, LP leaks, brake issues), file a complaint with NHTSA; patterns can trigger investigations and recalls.
- FTC and state Attorneys General: deceptive advertising or sales practices (e.g., misrepresenting the condition as “new and defect-free”) can fall under consumer protection statutes.
- Binding arbitration/mediation: Some purchase agreements require this; consult an attorney specializing in RV cases before signing or disputing.
Document defects with photos/videos, log dates the coach is out of service, and demand written ETAs. If you believe your rights are being violated under warranty or consumer protection laws, consult a consumer attorney.
Signs of Incremental Improvements
To maintain objectivity: some owners report satisfactory experiences with later-model Excursions after resolving initial punch-list items. In various recall bulletins and service advisories, component suppliers and REV Group have issued fixes (e.g., updated sensors, bracket reinforcements, sealant improvements). When recalls are properly handled and coaches are maintained proactively, many defects are manageable. However, the depth of owner complaints about water intrusion, slide mechanisms, and service delays suggests that diligence and third-party verification remain essential for this model family.
For buyer education and industry context, explore Liz Amazing’s RV buyer warnings; search her channel for the model/year you’re considering to cross-check your checklist.
Pre-Purchase Checklist Specific to the Fleetwood Excursion
- Roof and walls: inspect cap seams, ladder mounts, skylight/vent cutouts, and slide-toppers. Use a moisture meter along front and rear cap transitions.
- Slide-outs: cycle each slide at least three times; watch for racking, listen for grinding; inspect top/bottom seals and measure even gaps. Bring a laser level.
- Chassis/emissions: have a Freightliner/Cummins shop scan for active/inactive codes; ask for DEF head part numbers and revision history; confirm recall closures.
- Electrical: test all circuits under load; check inverter/charger function; trigger GFCIs and reset; verify battery age and condition report.
- Hydraulic: check jack rams for leaks; operate auto-level on a slope; confirm reservoirs at spec.
- Exterior: inspect for paint checking/cracking; examine awning brackets for movement; run awnings through full extension/retraction.
- HVAC/generator: 60-minute load test; verify delta-T on A/C; check furnace ignition cycles; ensure generator doesn’t stumble under combined A/C loads.
- LP/Appliances: confirm refrigerator recall compliance; pressure test LP system; inspect furnace/WH exhaust for proper clearance.
- Weight and tires: get four-corner weights; verify tire age (DOT code) and set pressures per load table; inspect for cupping or sidewall checking.
- Records: request a full service history and proof of recall completion; avoid “we’ll mail it to you later.”
Strongly consider hiring an independent inspector: Search RV inspectors near me.
Where to Verify and Cross-Check Owner Claims
- Video walk-throughs and failure diaries: YouTube search: Fleetwood Excursion Problems
- Recall and safety: NHTSA: Fleetwood Excursion
- Community deep-dives: Good Sam Community, RVInsider model complaints (search “Excursion”)
- Reddit: r/rvs • r/RVLiving • r/GoRVing
- BBB and consumer complaints: BBB search and PissedConsumer (enter “Fleetwood Excursion” in site search).
- Facebook owner groups: use this Google search to find Excursion-only groups with repair photos and parts sources.
For broader consumer advocacy, see Liz Amazing’s industry-exposing videos and then search her channel for “Fleetwood Excursion” or the model year you’re evaluating.
Have you solved a recurring Excursion issue? Post your tips for other buyers.
Model-Year Nuances and Context
Excursion production has spanned several distinct eras. Depending on year, you may encounter different slide mechanisms, multiplex systems, awning suppliers, and chassis electronics. When researching, always include the specific model year and floorplan in your searches. Examples of model-year-sensitive issues owners report include:
- Slide architecture changes: earlier Schwintek vs. later heavy-duty racks; full-wall slides often carry more risk than short slides if alignment isn’t perfect.
- Appliance generations: refrigerator models with varying recall histories; A/C units with different control boards.
- Chassis calibrations: DEF head and NOx sensor part-number updates over time; ensure the coach you’re buying has the latest revisions.
Because of these variations, don’t assume a fix on one year applies to all. Verify via recall bulletins and owner threads for the exact year. And if you’ve experienced a year-specific quirk, let other shoppers know in the comments.
Pricing, Options, and “Value” Reality Check
(Moderate Concern)
Owners frequently question whether the Excursion’s premium diesel-pusher price matches the delivered quality—especially after factoring in punch-list repairs and downtime. Options like full-body paint, upgraded entertainment, and residential fridges sound enticing but add complexity, heat load, and repair risk. Pay close attention to the “must-have” list versus the maintenance overhead of those systems. The value equation often hinges on how well a specific unit was built, stored, and maintained—so condition trumps features.
- Tip: Price in a “first-year” repair cushion (many owners budget $3,000–$7,500 for post-purchase remediation on used diesel pushers).
Due diligence threads: Excursion overpriced? and Ownership costs videos.
Bottom Line and Recommendation
The Fleetwood Excursion wins points for compact diesel drivability and floorplans that live larger than their length. Yet owner-reported patterns—water intrusion/delamination, slide failures, emissions derates, electrical gremlins, and long service delays—represent material safety and financial risks if not identified and resolved before purchase. If your heart is set on an Excursion, the path to a good outcome is narrow but achievable: exhaustive pre-purchase inspection, proof of recall compliance, professional slide calibration, and a seller who will remedy defects before delivery with a written punch-list. Verify all claims through the sources linked above, talk directly to multiple owners, and watch consumer watchdog content like Liz Amazing’s channel to calibrate expectations.
Given the density and seriousness of documented issues, we do not broadly recommend the Fleetwood Excursion to most shoppers unless a particular unit passes a rigorous third-party inspection with verifiable repair history and closed recalls. Consider expanding your search to alternative brands or models with stronger reliability records and owner satisfaction.
Owner Comments and Real-World Reports
What did we miss, or what confirmed your experience? Your detailed comment can help another family avoid a costly mistake. Please include your model year, floorplan, major issues encountered, and how they were resolved.
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