I had the same issue with mine but found it on our shake down trip. HOWEVER, the repair my dealer made still had a small bubble that later got worse. CR would not claim any blame or cost since it was past the 2 years. Because of the other damage that was caused by the bubble getting larger I had to have the front 5 ft replaced at my cost.
After buying mine I had the following issues, after reading were common with the PP, front roof meeting at the cap, graphics cracking, and the water hose at the fresh water tank leaking when full.
Since time of buying the camper I have continued to check the roof and reseal any crack in the sealant. I think in 05 they had a problem on the production line.
George and Debi
2006 F250 PSD, 2005 PF30CK