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Old 01-28-2022, 08:46 AM   #1
Join Date: Mar 2018
Posts: 31
Door Frame Cracked and Lock Issues

Good morning,

We have a 2018 Fleetwood Discovery LXE. The door frame is cracked, and as normal, warranty does not cover it (rough cost to replace it is around $4,900.
We are currently looking at the potential to remove the inboard panels and have it professionally re-welded and possibly reinforced.

Have any of you had broken door frames, and if you did, what did you do with it?

The second issue is trying to remove the electric door lock assembly, which I believe is a TriMark 17217-02. The lock while trying to remove it is connected to something on the inside that you can barely see. Is is connected by a bolt/nut or how is it connected? My concern is how to remove it and then having a major issue reconnecting it.

Thank you for any help you can give in this area.

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Old 01-28-2022, 08:53 AM   #2
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Pics would help.
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Old 01-28-2022, 08:59 AM   #3
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Having trouble attaching the pictures.
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Old 01-28-2022, 09:05 AM   #4
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Cracked Door

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Old 01-28-2022, 09:09 AM   #5
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That is very fixable for much less than the cost of a new door.
It will have to be taken apart, and a good TIG welder (the person) would be needed.
So, find the welder and go from there.
You can make it easier to get a quote by taking the interior panels off and then drive it to a welding shop for their quick inspection and plan.
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Old 04-05-2022, 06:46 AM   #6
Join Date: Mar 2018
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As information, we checked with Challenger Door, the manufacturer of the door. Of course, it's out of warranty. I also checked with the RV dealer where we purchased this RV. I talked to the service department asking them if they have had others ask them about their cracked door, and yes, they have had a few, so this is not an isolated issue. The service tech said once they got the price to replace it, everyone so far has walked away. I'd like to hear from others who have had the cracked door issue. Once we get home I'm going to try to find a good TIG welder and get their thoughts to repair the crack. The top portion of the door vibrates a lot and I doubt even welding it will stop the vibration.
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Old 04-05-2022, 08:07 AM   #7
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A good welder should have no problem fixing/reinforcing that. Might be the source of your vibration, too.

Saw a door cracked even less conspicuously & the owner demonstrated how the top half would actually flap when he shook the door.
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Old 04-05-2022, 04:42 PM   #8
"Formerly Diplomat Don"
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Location: Moorpark, Ca.
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I reoriented your photos.

Is the door flexing or just cracked? If just cracked, I would talk to a welder before removing it. They could probably weld it in place unless it needs reinforcement or is bent/tweaked.

They also have some plastic that gets heated and dribbles in small strings, kind of like a 3D printer. I can't remember where I saw it, but you can dribble the stringy material onto your damaged plastic panel and possibly make it look better, plus reinforce it.

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Don & Mary
2019 Newmar Dutch Star 4018 (Freightliner)
2019 Ford Raptor
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door, frame

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