Fleetwood-Expedition RV Exposed: Recalls, Slide Leaks, DEF Derates & Hidden Repair Costs
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Fleetwood-Expedition
Location: 1031 US-224, Decatur, IN 46733
Contact Info:
• ownerrelations@fleetwoodrv.com
• Support 800-322-8216
• Local 260-728-2121
Official Report ID: 1184
Fleetwood Expedition: What Shoppers Need to Know Before Buying
AI-powered research tools have systematically collected and analyzed public information to produce this report. The Fleetwood Expedition is a Class A diesel pusher coach historically built on Freightliner chassis with Cummins power, positioned as a mid-to-upper tier motorhome in Fleetwood’s lineup. For many years it represented a popular “step up” from gas coaches with promises of diesel durability, residential amenities, and long-haul comfort. However, owner reports across forums, reviews, and complaint boards reveal persistent quality-control concerns, service delays, and expensive post-sale repairs—issues that can dramatically affect the safety, usability, and total cost of ownership.
Below we consolidate recurring consumer-reported problems and risk areas so buyers can make a more informed decision, verify issues via credible sources, and avoid preventable surprises.
Community Research Shortcuts: Where to See Unfiltered Owner Reports
- Facebook owner groups (via Google search): Join multiple Fleetwood Expedition groups to compare unfiltered owner experiences and maintenance logs. Use this search: Fleetwood Expedition Facebook Groups (Google)
- YouTube: Watch owner walk-throughs, tear-downs, and complaint compilations: YouTube search: Fleetwood Expedition Problems. Also see Liz Amazing’s RV quality investigations and search her channel for “Expedition” to learn how she’s helping expose widespread RV quality issues.
- Better Business Bureau (BBB): Check patterns of complaint topics and resolution responses: BBB search: Fleetwood Expedition
- Reddit communities: Real-world fixes and cautionary tales from full-timers and weekenders:
- RVInsider and Good Sam Community: Aggregated owner reviews, maintenance notes, and repair journeys:
- NHTSA Recalls: Confirm safety recalls by model and year: NHTSA recalls: Fleetwood Expedition
- Forums with deep archives: Use each site’s search for “Expedition” and “problems”:
- Complaint boards: Browse brand-level complaints to spot recurring patterns (search manually for “Fleetwood Expedition”): PissedConsumer
Have you experienced a chronic issue with your Expedition? Add your story to help other buyers.
Get a Third-Party RV Inspection Before You Buy
A thorough, independent inspection is your only real leverage before signing. Once a dealer has your money, multiple owners report being pushed to the back of the service line—leading to cancelled trips and coaches sitting for months awaiting parts or technician time. Book an inspector early and make your purchase contingent on a clean report. Start here: Search: RV Inspectors near me.
- Scope to require: chassis health (engine, transmission, cooling, brakes), roof/sidewall moisture testing, slide-out operation and alignment, inverter/ATS tests under load, generator load testing, and a detailed water leak and plumbing pressure test.
- Deliverables to demand: written report, photo/video documentation, and a repair estimate you can use to negotiate price and hold-back funds.
If you’ve already owned an Expedition, what did your pre-delivery inspection miss? Tell shoppers what to watch for.
Patterns of Reported Defects and Service Failures
Chassis and Powertrain (Freightliner/Cummins)
(Serious Concern)
DEF sensor failures and emissions-related derates. For later-model diesels, owners regularly report Diesel Exhaust Fluid (DEF) quality sensor failures and emissions system glitches that force engine derates and limp modes—sometimes far from service centers. This can strand travelers roadside and trigger costly tows. Research these threads and service bulletins before a long trip, and ask sellers for documentation of any DEF head replacements or software updates. Evidence and context: Google: Fleetwood Expedition DEF sensor Problems, YouTube: Expedition Problems.
(Moderate Concern)
Steering wander, alignment, and ride complaints. Some owners report front-end wander, steering play, or harsh ride until a professional alignment, ride-height check, or suspension upgrades (e.g., shocks, steering stabilizer) are performed. While often fixable, these concerns increase fatigue and can be dangerous in crosswinds. Check for up-to-date alignment records and tire age/pressure consistency. See discussions: Reddit: Expedition handling problems, Google: Steering wander.
(Moderate Concern)
Cooling system and exhaust components. Reports include intermittent overheating under load, charge-air-cooler leaks, or EGR-related maintenance on certain Cummins engines. Buyers should scrutinize service records for coolant flushes, thermostat replacement, and radiator maintenance. References: Google: Expedition overheating.
Structural Integrity: Slides, Roof, Sidewalls, Windshield
(Serious Concern)
Slide-out leaks and floor damage. Recurring owner narratives cite slide seals that flatten or misalign, water intrusion at slide corners, and resulting subfloor deterioration or delamination. Look for soft floors near slide transitions, swollen trim, or staining. Insist on pressurized leak testing and slow, repeated cycling of each slide during inspection. Verification: Google: Expedition slide-out problems, Good Sam: slide problems.
(Serious Concern)
Sidewall delamination. Multiple posts across forums describe bubbling/flexing fiberglass sidewalls, often tied to moisture ingress or adhesive failure. Delam is expensive to fix and can rapidly worsen. Use a moisture meter and sight lines under bright light to detect waves or blisters. Research threads: Google: Expedition delamination, RVForums (search “Expedition delam”).
(Serious Concern)
Windshield bonding and cap flex. Some owners report windshields “popping” or separating due to cap flex or insufficient bonding, especially after rough roads or chassis twist. This can quickly become a safety hazard. Inspect for previous sealant work, glass breakage history, and stress cracks near the A-pillars. Sources: Google: Expedition windshield problems, YouTube: Expedition problems.
(Moderate Concern)
Roof seam failures and sealant maintenance. Owners frequently note cracked sealant at roof junctions, around antennas, and at front/rear caps. Neglected seams can lead to hidden water damage. Annual resealing is essential. Verify maintenance logs and climb the roof with your inspector. References: Google: Expedition roof leak problems.
Electrical and Electronics
(Moderate Concern)
Multiplex/control panel failures and phantom drains. Reports include sporadic lighting, inoperative switch banks, and rapid battery depletion. Failures in Intellitec/Firefly-style systems or weak house batteries can cascade into inconvenient outages. Test all circuits under shore power and battery only. Sources: Google: Expedition electrical problems, RVInsider: Expedition problems.
(Moderate Concern)
Automatic Transfer Switch (ATS), inverter/charger, and generator hiccups. Owners document ATS arcing, inverter/charger faults, and generators that won’t carry listed loads. These can be fire risks if neglected. Insist on a heavy-load test for A/Cs and microwave while switching power sources. Learn more: Good Sam: Electrical problems, Reddit: Generator problems.
Plumbing, Wet-Bay, and HVAC
(Moderate Concern)
Wet-bay leaks, PEX fittings, and tank sensor inaccuracies. Leaks in the wet-bay and persistent false readings on tank sensors are common RV-wide, and Expedition owners report their share. Look for swelling, corrosion at fittings, and staining. Pressure-test the water system. Citations: Google: Expedition water leak problems.
(Moderate Concern)
A/C ducting and condensate management. Some owners describe weak airflow to the bedroom, noise, or condensate dripping back into the coach. Test each zone under high ambient temps and verify clean returns/filters and proper duct seals. Threads: Reddit: Expedition A/C problems.
(Moderate Concern)
Furnace and hydronic heating quirks. Owners report intermittent ignitions, pump leaks (hydronic), and control board failures—often seasonal and not discovered until the first cold snap. Test all heat sources at handoff. See: Google: furnace problems.
Appliances and Amenities
(Serious Concern)
Refrigerator recalls and performance complaints. Across brands and years, absorption refrigerators have had recall campaigns (fire risk), and owners cite poor cooling in hot climates. Confirm recall closure on your specific unit and consider the service history or a 12V compressor retrofit. Validation: NHTSA recall database (search your year), Google: Expedition refrigerator recall.
(Moderate Concern)
Awnings and slide toppers. Common reports include ripped fabrics, failed motors, and misaligned arms. Inspect carefully for chafe points and ask for documentation of replacements. See: Good Sam: Awnings problems.
Fit, Finish, and Interior Materials
(Moderate Concern)
Cabinetry alignment, trim gaps, and rattles. Owners highlight misaligned doors, loose trim, and squeaks that worsen over time. Inspect all doors/drawers underway to catch rattles, and look for evidence of re-screwing or bracing. References: RVInsider: Expedition owner reviews.
(Moderate Concern)
Upholstery (peeling “ultraleather”). Premature peeling of synthetic seat materials is a frequent complaint across several RV brands. Expedition owners have echoed similar issues, especially on high-use captain’s chairs. Check for reupholstery invoices or seat covers. More: Google: Expedition peeling seats.
Warranty, Dealer Service, and Parts Delays
(Serious Concern)
Long repair timelines and cancellations of planned trips. Owners consistently report months-long service backlogs and parts delays, resulting in “camping season lost” while the RV sits at the dealer. This is particularly painful for full-timers or those with limited travel windows. Cross-check complaints and timelines: BBB complaint patterns, Google: Expedition warranty problems. Also see Liz Amazing’s videos on dealer backlogs and search her channel for “service delays”.
(Serious Concern)
Warranty denials and limited goodwill support. Some complaint narratives allege that certain failures were deemed “wear-and-tear” or outside coverage windows despite low mileage or age. Always keep meticulous records and escalate respectfully in writing. Research: Google: Expedition warranty complaints, Reddit: Expedition warranty.
(Serious Concern)
Parts availability and factory communication. Owners frequently cite slow parts pipelines and challenges reaching responsive contacts for status updates. If you buy used, document model/year for all subcomponents (slide mechanisms, A/C model numbers, inverter make) to speed sourcing. Evidence: RVInsider: parts complaints, Google: Expedition parts delay.
Have you waited months for a single part? Report your timeline for others to compare.
Recalls and Safety Alerts: What Owners Should Check
The Expedition spans many years and configurations. Recalls may involve chassis components (brakes, steering, axles), electrical systems, and appliances (notably refrigerators). Confirm any recall status by VIN before purchase or travel. Start with the federal database for your year and model: NHTSA recall lookup: Fleetwood Expedition. Use this alongside owner videos and walkthroughs: YouTube: Expedition Problems.
- Ask the seller for proof of recall completion and keep copies of all work orders.
- Inspect safety-critical systems (brake lines, steering linkage, fuel lines) with a qualified inspector. If any open recalls remain, defer delivery until completed.
Legal and Regulatory Warnings
Consumer complaints tied to safety, warranty performance, or deceptive practices may trigger protections under state and federal law. While every case is fact-specific, here are frameworks to know:
- Warranty enforcement: The Magnuson–Moss Warranty Act prohibits deceptive warranty practices and enables consumers to pursue remedies for unfulfilled written warranties. Keep detailed records of repair attempts and communications. If you suspect a pattern of warranty denials despite clear coverage, document dates, dealer statements, and costs.
- State Lemon Laws: Motorhome coverage varies by state; some treat the chassis differently from the “house.” If repeated repairs fail to fix substantial defects within a reasonable time, consult a Lemon Law attorney in your state.
- Safety defects: If you experience a defect that poses a safety risk (e.g., brake failure, engine derate in traffic, electrical fire risk), file a complaint with NHTSA and retain evidence. This can help trigger investigations and recalls.
- Deceptive trade practices: If sales claims materially differ from the delivered product (amenities not installed, misrepresented towing capacities), you may have claims under state consumer protection statutes and could also report to the FTC.
Research examples and complaint structures at: BBB (Fleetwood Expedition), Google: Expedition complaints. For broader industry oversight and best practices, see more commentary from Liz Amazing’s channel—then search her videos for “warranty,” “dealer delays,” and your specific model year.
Product and Safety Impact Analysis
A pattern emerges: several Expedition owners encounter structural water intrusion, slide malfunctions, and electrical anomalies early in ownership—compounded by long repair queues. Here’s how those risks translate into safety and financial exposure:
- High safety impact: engine derate on grades or in traffic due to emissions faults; windshield bonding issues; ATS arcing; water intrusion leading to hidden mold and soft floors around exits.
- High financial impact: sidewall delamination; roof leaks causing substructure repairs; repeated slide re-adjustments and motor replacements; upholstery re-trim; out-of-warranty generator or inverter failures.
- Trip reliability impact: owners report cancellations and lost deposits when repairs drag out for months—particularly during peak season when dealer bays are booked.
To reduce exposure, make inspection findings part of your negotiation, build a repair reserve, and pre-identify independent shops (not just the selling dealer) for faster service scheduling. Consider a second search for professionals: Find an RV inspector near me.
Do you feel certain issues rise to the level of a safety defect? Tell us what happened and how it was resolved.
Cost Exposure and Resale Implications
- Delamination repair: Often not economical; can run into five figures or render a coach “sell as-is.”
- Roof remediation: Reseal and cleanup can be thousands; a full roof replacement higher.
- Slide repairs: Motor/gearbox/seal work stacks up; water-damaged floors escalate costs.
- Upholstery: Reupholstering driver/passenger seats and dinette can be a significant surprise expense.
- Electrical: ATS/inverter replacement and diagnostic labor accrue quickly; misdiagnosis is common.
- Emissions system faults: DEF sensors or SCR components can be pricey and trip-critical.
Given these exposures, resale value hinges on maintenance records. Buyers discount heavily for any signs of water damage or structural repair, so thorough documentation and preventive maintenance are critical.
Signs of Incremental Improvement and Manufacturer Responses
Some owners report positive experiences with individual dealers or technicians who went above and beyond to resolve lingering defects, and certain recall campaigns have been successfully closed per NHTSA records. Going through official service channels for chassis (Freightliner/Cummins) versus “house” items can speed specialized repairs. However, persistent owner narratives still emphasize slow parts pipelines and inconsistent quality control.
Balanced diligence is key: verify improvements on your specific VIN with receipts, recall closures, and verification that high-risk systems (slides, roof seams, windshield bonding) have been addressed or upgraded. Use the archives here to validate claims: YouTube search, Google: Expedition issues, and RVInsider: Expedition owner experiences.
Pre-Purchase Checklist for Fleetwood Expedition Shoppers
- VIN-level recall check: Run your year and model through NHTSA: NHTSA recall lookup.
- Moisture mapping: Use a meter on slide floors, behind cabinetry on exterior walls, at roof seams, and around windshield/A-pillars.
- Slide audit: Cycle each slide multiple times, listen for binding, and inspect seals and under-slide floors for rot or gaps.
- Electrical load test: With A/Cs and microwave running, switch power sources to confirm ATS/inverter stability.
- Chassis exam: Verify service intervals, coolant condition, alignment specs, tire date codes, and any DEF/emissions repair history.
- Appliance verification: Refrigerator temperature test in hot conditions; verify any recall closures. Check furnace/hydronic systems under load.
- Interior wear: Inspect seat coverings, trim alignment, and cabinet fastenings while driving on a bumpy test loop to expose rattles.
- Warranty and service plan: If dealer-sold, get commitments in writing for fix timelines and loaners when available.
- Independent inspection: Make the sale contingent on a clean third-party report: Find a certified RV inspector.
Want to add a checklist item for future shoppers? Post your must-check items.
Additional Sources to Verify Complaints and Solutions
- Owner videos: YouTube: Expedition Problems
- Consumer reports and reviews: RVInsider, Good Sam Community
- Aggregated complaints: BBB search, Google: Expedition complaints
- Forums: Search “Expedition” and “problems” within RVForums.com, RVForum.net, and RVUSA Forum.
- Industry advocates: Learn how creators are documenting systemic quality issues—start with Liz Amazing’s RV quality exposés and search her channel for your model/year to see related advice.
Balanced Notes: When Owners Report Good Experiences
Not all expeditions into Expedition ownership are negative. Some owners cite many happy miles after addressing early bugs: upgrading shocks, resealing roof seams proactively, and keeping meticulous maintenance schedules. A few highlight strong dealer relationships and responsive factory tech support in specific cases. These narratives tend to correlate with rigorous pre-delivery inspection, fast-follow maintenance, and budgeting for early upgrades.
Still, the weight of consumer reporting indicates that proactive diligence isn’t optional—it’s essential. Consider also following advocates who push for transparency and accountability, such as Liz Amazing’s channel on dealer and warranty pitfalls, then search for “Expedition” to see any model-specific insights.
Bottom Line: Should You Buy a Fleetwood Expedition?
The Expedition’s appeal—diesel power, roomy layouts, and the promise of long-haul comfort—remains strong on paper. Yet across the consumer record, we see recurrent patterns: water intrusion (especially at slides and roof seams), structural concerns like delamination and windshield bonding, electrical/ATS problems, emissions/DEF failures causing derates, and long, costly repair cycles with limited warranty satisfaction in some cases. For shoppers determined to pursue an Expedition, a third-party inspection, meticulous VIN-level recall checks, and a realistic repair reserve are non-negotiable.
Given the depth and frequency of documented issues, we cannot broadly recommend the Fleetwood Expedition to risk-averse buyers. If you move forward, purchase only after an independent inspection and aggressive price concessions—or consider alternative brands/models with stronger reliability records documented through owner forums, BBB patterns, and NHTSA recall histories.
Have you solved a difficult Expedition problem others could learn from? Share your fix for the community.
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