WELD PROBLEMSHere is a copy of an email I received from Fleetwood regarding the weld issue on some 1998 and prior year D's:
Thank you for sharing your information with us.   We are dedicated to
assuring our Discovery owners of the ongoing value and safety of their
Discovery motor homes.   Please forward any information from members
regarding these or any Discovery concerns to our email address at
email@example.com.   Of course, we are always ready to assist our
customers by calling one of our Owner Relations staff at 1-800-322-8216,
open 7 days a week.
Let me address each issue you mentioned:
We are continuing our investigation of Discovery's for condition of under
chassis components, primarily the frame to platform welds on 1996 - 1998
Discovery's.   I participated in the Tucson rally and truly appreciate the
warm reception we received from our Discovery friends and owners.
At the Tucson Rally, we inspected 122 coaches and have provided our reports
to the Fleetwood Engineering Group for review.   From those inspections, I
requested 3 units be repaired by the exceptional service staff at Beaudry's
RV.   We repaired the three units due to broken welds that could have allowed
movement of the platform to chassis if not repaired.  All of the Discovery's
we inspected, including the three repaired coaches, were and are
structurally sound and safe to drive.   The repairs were completed to prevent
further movement from occurring.
As we continue our investigation, including the Reyne Rally, we will keep
your members informed of our findings.
Mr.  Myhre has provided Fleetwood copies of the photos of the lower slide
brace and it's proximity to the under chassis tanks.   We are evaluating this
issue at the moment and do not have suggestions yet.   We will provide a more
complete reply once we have inspected this issue first hand.
I will be attending the Reyne Rally to be available to discuss these and any
other concerns Discovery owners may have.   We are very confident we can
provide answers and resolution to any and all open issues at that time.
Please remind your Discovery Owner members to contact Fleetwood Owner
Relations at 800-322-8216 if they have any concerns about their Discovery's.
We are proud of the exceptional value, quality and durability of the
Discovery motor home and want to provide any support to your members may
As we have come to expect, Fleetwood is very interested in our safety and concerns.   Fleetwood advises that the weld problem does NOT affect the safety of the D.   However, several members with weld problems that had their D fixed at the Tuscon rally advise that their coach handles significantly better.
Thursday, April 18 Update, Decatur, IN
Also, some 2000 model coaches are having a possible weld problem, but this does not involve the PACO beam as on the 1997 and prior production coaches.   This involves welding on the luggage bays, from what I understand.
You may still want to inspect your D for missing, poor or broken welds along the PACO beam, especially in back of the front and rear tires.   Here is a picture from Denny that shows what to look for.
Although not confirmed by Fleetwood, it is believed that you should have a weld every 6 inches.
After you inspect your coach, it is very important that you send the following information to Denny at DMyhre943@aol.com, and copy Bob Cook at firstname.lastname@example.org.   Also, please let Fleetwood know if you find a weld problem.   We ALSO need to hear from you if you do NOT find this problem!