2003 Damon CHALLENGER: complaints, problems and recalls

PASSENGER SIDE REAR SPRING SHACKEL RUBBED AGAINST THE MOTORHOMES PROPANE TANK. DEALER PAID FOR ADJUSTMENT TO PROPANE TANK HOLDING STRAP. *TT

Owner-reported narrative. Look up ODI 10020821 at NHTSA ↗

DRIVER'S AND PASSENGER'S SUNVISORS CAN BE REACHED FROM THE SEAT, ARE USELESS. DEALER NOTIFIED. *AK

Owner-reported narrative. Look up ODI 10024233 at NHTSA ↗

INSIDE COMPARTMENT DOORS DON'T HAVE SUPPORT, THIS IS SAFETY A SAFETY ISSUE THEY WERE NOT WELL DESIGNED. DEALER NOTIFIED. *AK

Owner-reported narrative. Look up ODI 10024235 at NHTSA ↗

THE CONSUMER IS CONCERNED ABOUT THE SUN VISORS ON THE MOTOR HOME. WHILE DRIVING, THE DRIVER HAD TO UNBUCKLE THE SEAT BELT AND STAND UP TO REACH THE SUNVISOR. ONCE THE VISOR WAS PULLED DOWN IT WAS TOO SHORT TO BLOCK THE GLARE OF THE SUN AND AS A RESULT THE DRIVER COULD NOT SEE WHILE DRIVING. *NM

Owner-reported narrative. Look up ODI 10057570 at NHTSA ↗

SUN VISORS CAN NOT BE REACHED WHILE SITTING. I HAVE TO PULL OVER TO THE SIDE OF THE ROAD TO ADJUST. AT TIMES THIS IS REAL DANGERIOUS SINCE MOST OF THE HIGHWAYS DO NOT HAVE PLACES WIDE ENOUGH TO ALLOW THIS. THIS PROBLEM HAPPENS ALL THE TIME, REAL BAD WHEN YOU ARE TRAVELING TO THE WEST.*AK

Owner-reported narrative. 1,000 miles reported. Look up ODI 10064067 at NHTSA ↗

STALLING WHEN IT RAINS. IT SEEMS THAT THE AIR FILTER IS RIGHT IN FRONT OF THE RIGHT FRONT WHEEL. WHEN IT RAINS THE FRONT TIRE KICKS UP WATER IN THE AIR FILTER HOUSING SOAKING THE AIR FILTER CAUSING THE ENGINE TO QUIT RUNNING. THIS HAPPENS EVERY TIME IT RAINS HARD. I HAVE TO REPLACE THE FILTER IN ORDER TO CONTINUE DRIVING. CARRYING EXTRA AIR FILTERS IS STARTING TO GET EXPENSIVE. RIGHT NOW I USE DUCK TAPE TO SEAL THE FILTER BOX. *NM

Owner-reported narrative. 19,000 miles reported. Look up ODI 10136118 at NHTSA ↗

TL*THE CONTACT OWNS A 2003 DAMON CHALLENGER, WORKHORSE RECREATIONAL VEHICLE. SHE RECEIVED A RECALL LETTER PERTAINING TO THE FAILURE (SEE NHTSA CAMPAIGN ID NUMBER: 09V225000, NHTSA ACTION NUMBER: EA07016, COMPONENT: SERVICE BRAKES, HYDRAULIC) AND TOOK THE VEHICLE TO THE NEAREST AUTHORIZED DEALER. BEFORE ANY REPAIR WORK WAS PERFORMED ON THE VEHICLE THE DEALER STATED THAT THE REPAIR WAS AT NO COST; HOWEVER, THE DEALER ADVISED HER THAT THE VEHICLE WAS READY FOR PICK-UP. THE REPAIRS COST WAS OVER $800 AND WOULD NOT BE COVERED BY THE MANUFACTURER DE…

Owner-reported narrative. 33,000 miles reported. Look up ODI 10301932 at NHTSA ↗

Reported: 2003-03-05 (March 5, 2003)

CERTAIN MOTOR HOME CHASSIS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." THE BRAKE SYSTEM WARNING INDICATOR MAY NOT FUNCTION AS REQUIRED BY STANDARD.

Consequence: IN SOME OF THE AFFECTED VEHICLES, THE BRAKE SYSTEM WARNING INDICATOR WILL NOT ILLUMINATE WHEN THE IGNITION IS IN THE START POSITION OR FOR A LOW BRAKE FLUID CONDITION, IF THE BODY BUILDER RELIED SOLELY UPON FORD'S IVM COMPLIANCE STATEMENT FOR THE BRAKE SYSTEM WARNING INDICATOR.

Remedy: DEALERS WILL REPAIR THE BRAKE WARNING LAMP CIRCUIT. OWNER NOTIFICATION IS BEGAN MAY 12, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAMON AT 1-219-272-9212.

Reported: 2006-04-24 (April 24, 2006)

CERTAIN MOTOR HOMES BUILT ON WORKHORSE CHASSIS AND EQUIPPED WITH ACTIA CORPORATE INSTRUMENT CLUSTERS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 101, "CONTROLS AND DISPLAYS" AND NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." IF THE BRAKE FAIL INPUT FALLS BELOW A VOLTAGE OF 1.5V, THE BRAKE FAILURE LAMP AND ALARM WILL BE ACTIVATED. ALSO ACTIVATION OF THE ABS TELLTALE WHEN THE ABS IS NOT PROPERLY FUNCTIONING DOES NOT ALWAYS OCCUR.

Consequence: AT NIGHT THE INSTRUMENT CLUSTER LIGHTS MAY FAIL AND THE DRIVER MAY NOT BE ABLE TO SEE THE INSTRUMENT PANEL GAUGES AND THE BRAKE WARNING LIGHT INDICATOR WHICH COULD INCREASING THE RISK OF A CRASH.

Remedy: DAMON IS WORKING WITH WORKHORSE TO CONTACT THE OWNERS AND REMEDY THIS CAMPAIGN . WORKHORSE WILL REPROGRAM THE INSTRUMENT PANEL CLUSTER FREE OF CHARGE. OWNERS MAY CONTACT WORKHORSE AT 1-877-246-7731 OR DAMON AT 1-800-860-3812.

Reported: 2007-03-20 (March 20, 2007)

CERTAIN TRAVEL TRAILERS AND MOTOR HOMES EQUIPPED WITH A TWO-DOOR REFRIGERATOR, MANUFACTURED BY THE DOMETIC CORPORATION, MAY HAVE A DEFECT IN THE BOILER TUBE. PRESSURIZED COOLANT SOLUTION COULD BE RELEASED INTO AN AREA WHERE AN IGNITION SOURCE (GAS FLAME) IS PRESENT.

Consequence: RELEASE OF COOLANT UNDER CERTAIN CONDITIONS COULD IGNITE AND RESULT IN A FIRE.

Remedy: DAMON WILL BE WORKING WITH DOMETIC IN ORDER TO REPAIR THESE REFRIGERATORS (PLEASE SEE 06E076). DOMETIC WILL REPAIR THESE REFRIGERATORS BY INSTALLING A SECONDARY BURN HOUSING, A THERMAL FUSE, AND A MELT FUSE FREE OF CHARGE. DOMETIC HAS RETAINED STERICYCLE INC. TO MANAGE THIS CAMPAIGN. STERICYCLE WILL ASSIST YOU IN LOCATING DEALERSHIPS OR SERVICE CENTERS AND WILL PROVIDE ASSISTANCE WITH SCHEDULING OF APPOINTMENTS. OWNERS MAY CONTACT DOMETIC/STERICYCLE AT 1-888-446-5157 OR DAMON AT 1-800-860-3812.

Reported: 2009-06-16 (June 16, 2009)

DAMON IS RECALLING 2,415 MOTORHOMES EQUIPPED WITH AXLES THAT INCLUDE BOSCH ZOPS OR ZOHT PIN SLIDE HYDRAULIC DISC BRAKES. WHEN COMBINED WITH OCCASIONAL OR SEASONAL VEHICLE OPERATION MAY EXPERIENCE CALIPERS STICKING IN THE APPLIED POSITION. THIS CAN RESULT IN ABNORMAL HEAT GENERATION AT THE WHEEL END CAUSING BRAKE DRAG.

Consequence: THE DRIVER WOULD NORMALLY DETECT THE BRAKE DRAG BUT IF UNDETECTED THE TEMPERATURE INCREASE AT THE WHEEL END CAN EVENTUALLY LEAD TO SOFT PEDAL CONDITIONS DUE TO BRAKE FLUID BOIL, AND POSSIBLE EXTENDED STOPPING DISTANCE INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT AND REPLACE THE NECESSARY COMPONENTS FREE OF CHARGE. WORKHORSE IS HANDLING THE REMEDY AND OWNER NOTIFICATION FOR THIS CAMPAIGN PLEASE SEE 09V-110. OWNERS MAY CONTACT WORKHORSE AT 1-877-246-7731.