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Old 07-13-2015, 09:59 PM   #1
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Front cap leak. Why?

In the spring of 2013 we bought a brand new 3171DS. We used the motorhome to travel from Calgary to Montreal and back (6 weeks) and on several weekend getaways. At the end of October we winterized and had the roof inspected by our selling dealer and put her away for the winter. In the spring of 2014 we pulled her out of storage and started another camping season.

In mid July 2014 (3 months out of warranty) I noticed the headliner in the overhead cab area was discoloured. I took it to my dealer and he broke the news we all hate to hear. Leak in the front cap. He then told me that I was out of warranty and that the cost to repair would be mine to cover. Great. I called Forest River and spoke to a guy (not sure what his name was) but he essentially told me you are out of warranty so pound sand. He didn't care if I was only 3 months out warranty, it was now my problem. A few days later we had a huge storm roll through and it dropped massive hail down on us causing some damage to my roof. I was able to get in and have it looked at by a repair shop the next day (the same repair shop my dealer used when I discovered the crack under my driver side slide). While there I mentioned the leak in the front cap. He climbed up and said something about a poor job of sealing it and caulked it for me. The repair was temporary for the summer and when they repair the hail damage they will fix the front cap leak as well. I drop off the motorhome mid October for repairs and pick up when it is done. I can't remember off hand what they did but they said good as new no more leak.

Fast forward to today. We are 5 days into a 5 week cross country trip 2300 KMs from home and we had a huge rain storm last night. The kids sleeping up top comment about rain drops on them during the night. I crawl up and the stupid headliner is all discoloured again and a small amount of water is dripping from the speaker above their heads. When I removed the speaker there was water in the cavity where the insulation is. Not much but enough to ruin the headliner and my day. I called the repair shop back home and they booked me in when I return but they are not sure what is going on.

Is it possible that the the front cap isn't securely fastened to the coach and while I drive it bounces around and breaks the seal? I am so frustrated now. I know the repair shop will fix it they normally do very good work, but could this be a bigger problem then just resealing. I'm upset that my dealer didn't want to fight for me the first time when I was only 3 months out of warranty, and I am upset that Forest River didn't step up. I get that no warranty is no warranty, but the motorhome is only 2 years old and I now have had 2 leaks in the front cap. It's not like it's a 10 year old piece of junk it's still smells new.

Sorry about the novel but I am very frustrated. This is our 3rd RV and by far the most troublesome unit I've owned. I did research on class c's and knew of the potential for leaks but never expected it on a brand new unit. We live the floor plan and the flexibility a motorhome offers us for traveling, but I kind of regret selling my fifth wheel.

Oh well. I'm sure everything will get fixed. I'm going to enjoy my vacation and worry about it when I get home. Sorry about the rant.
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Old 07-13-2015, 10:27 PM   #2
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Sorry to hear about your roof problems. I was actually interested in the part where you said you found a crack under your slide. I have a 2015 3010 that I posted about a crack in my fiberglass under the slide and didn't really have anyone say they had the same problem. Mine is probably a few inches wide right next to the rear track. When the slide comes in it rests above a thick piece of metal, probably 1/2" to 3/4" thick. It's about the only thing I can see that would make a crack in that area. Can you describe where yours was, what caused it and how you fixed it? Thanks.
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Old 07-13-2015, 10:43 PM   #3
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I bought a Forest River because they bragged about the no leak front cap. Our Minnie Winnie always leaked in the front but that had a window in the front. Sure hope someone from Forest River can come to the rescue and figure out what the problem is with your unit.
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Old 07-14-2015, 08:19 AM   #4
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In 2013 at the end of the season the roof was inspected and they didn't find any issues with the seals around the front cap, then in 2014 you pulled it out of storage and that's when you had issues? Was your unit indoors all winter long?
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Old 07-14-2015, 10:07 AM   #5
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The unit was outside over the winter.
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Old 07-14-2015, 11:44 AM   #6
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Our warranty guys work hard to help everyone that calls or comes in. Could there have been any other circumstance besides a factory issue that caused said leak? If I'm not mistaken the climate in Alberta changes almost as frequently as it does in the Midwest. One day it could be Sunny and not a bit of snow on the ground but by 8PM that same day we have a foot of snow and below zero temperatures. Maybe the changing climate had an effect on it over winter.
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Old 07-14-2015, 11:56 AM   #7
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Quote:
Originally Posted by Joshua Cavitt View Post
Our warranty guys work hard to help everyone that calls or comes in. Could there have been any other circumstance besides a factory issue that caused said leak? If I'm not mistaken the climate in Alberta changes almost as frequently as it does in the Midwest. One day it could be Sunny and not a bit of snow on the ground but by 8PM that same day we have a foot of snow and below zero temperatures. Maybe the changing climate had an effect on it over winter.
Are these units not made for changing climates? I think there will be a lot of disappointed people out there if this is the case.
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Old 07-14-2015, 12:08 PM   #8
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They are more than capable in changing climates. These are just questions to help get to the bottom of your problem.

We are continually improving our product and features which include our cap.
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Old 07-14-2015, 12:45 PM   #9
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Our 2012 Forester developed a leak in front cap shortly after purchase.
Upon checking it was found that water was coming through front cab light over the drivers area. The lends was then sealed by service department. They also replaced all areas that was damaged by water.
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Old 07-14-2015, 12:46 PM   #10
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The climate does change often but, the front cap was repaired in early spring. I picked it up just before the May long weekend, so I don't believe climate would have caused this leak. I am wondering if it is because of road vibration. Another possible point of entry could be the clearance lights. We did drive through some rain but not that much.
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