2005 Damon INTRUDER: complaints, problems and recalls

CONSUMER CONCERNED ABOUT SAFETY OF 2005 DAMON INTRUDER. *TS ***NO ANSWER REQUIRED*** IN DEC 2005 THE CONSUMER RECEIVED FOLLOW UP RECALL NOTICE FROM WORKHORSE CUSTOM CHASSIS, IN WHICH THEY ENCLOSED THE ORIGINAL NOTICE DATED DEC 2004. THE CONSUMER DIDN'T TAKE POSSESSION OF THE RV UNTIL MARCH 2005. WHEN THE CONSUMER PURCHASED THE RV IT WAS NOT MENTIONED THAT A RECALL HAD BEEN ISSUED. THE CONSUMER IS NOW REQUESTING ANY AND ALL PAPERWORK OF REPAIRS THAT WAS PERFORMED ON THE VEHICLE. *JB

Owner-reported narrative. Look up ODI 10149751 at NHTSA ↗

TL* THE CONTACT OWNS A 2005 DAMON INTRUDER. WHILE DRIVING APPROXIMATELY 60 MPH, THE CONTACT BEGAN TO HEAR AN ABNORMAL WHISTLING NOISE. THE VEHICLE WAS PULLED OVER AND PARKED. HE STATED THAT HE COULD SEE A GAP BETWEEN THE WINDSHIELD AND THE FRAME OF THE VEHICLE FROM THE FRONT PASSENGER SIDE. AN AUTHORIZED DEALER WAS NOTIFIED AND THE CONTACT WAS INFORMED THAT IT WAS A KNOWN FAILURE, BUT THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 12,000.

Owner-reported narrative. 12,000 miles reported. Look up ODI 10359096 at NHTSA ↗

AUTO PARK BRAKE LOCKS UP, TRAVELING DOWN THE HIGHWAY. THIS HAPPENED 4 ADDITIONAL TIMES: 02/28/2007; 02/29/2008; 03/02/2010; & 02/01/2011. WE ARE IN FEAR THAT WE MAY BE KILLED AND MAYBE ENDANGERING THE LIVES OF OTHERS EACH TIME THIS HAPPENS. ON 08/04/2009, THE AUTO PARK BRAKE FAILED TO HOLD WHEN WE PARKED. THE MOTOR-HOME STARTED ROLLING BACKWARD, SO WE HAD TO BLOCK THE TIRES. EACH TIME WE HAD THE AUTO PARK BRAKE REPAIRED THROUGH WORKHORSE - AND EACH TIME IT HAPPENED AGAIN!!!

Owner-reported narrative. 21,799 miles reported. Look up ODI 10388610 at NHTSA ↗

PER REPAIR FROM FLEET PAINTING INC., MAY 18, 2012: MAY 18, 2012 RE: 2005 DAMON INTRUDER RV TO WHOM IT MAY CONCERN: IN REGARDS TO THE LEFT SIDE FRONT CAP, MANUFACTURER DEFECT IN TOP CORNER. THE CAP RADIUS ON THE WINDOW OPENING DOES NOT MEET THE CURVE OF THE FRONT WINDSHIELD, SO THE WINDSHIELD WILL NOT STAY IN PLACE AND WILL NOT SET CORRECTLY. THIS CREATES AN OPENING TO THE FRONT CAP. ADDITIONALLY THE RIGHT SIDE LOWER FRAME SUPPORT WAS CRACKED & SHIFTED ADDING TO THE PROBLEM WITH THE WINDSHIELD. TO CORRECT THIS DEFECT WE HAD TO RECONSTRUCT T…

Owner-reported narrative. 42,030 miles reported. Look up ODI 10461971 at NHTSA ↗

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: 2006-06-30 (June 30, 2006)

CERTAIN MOTOR HOMES BUILT ON WORKHORSE CHASSIS MAY HAVE BEEN EQUIPPED WITH INCORRECT STEERING INTERMEDIATE SHAFTS. THE SPLINE CAN STRIP WHILE THE STEERING WHEEL IS BEING TURNED.

Consequence: THIS STEERING CONDITION COULD RESULT IN A LOSS OF STEERING CONTROL, INCREASING THE RISK OF A CRASH.

Remedy: WORKHORSE IS CONDUCTING THIS RECALL (PLEASE SEE 06V148000) AND WILL INSPECT AND, IF NECESSARY, REPLACE THE STEERING INTERMEDIATE SHAFT. OWNERS MAY CONTACT WORKHORSE AT 1-877-294-6773 OR DAMON AT 574-264-2900.

Reported: 2006-11-28 (November 28, 2006)

ON CERTAIN MOTOR HOMES BUILT ON WORKHORSE CHASSIS AND EQUIPPED WITH GM 8.1L V8 ENGINES, IMPROPER HARDENING DURING THE HEAT TREATMENT PROCESS CAN CAUSE THE FUEL RAIL PULSE DAMPER RETAINER CLIP TO FRACTURE, RESULTING IN INADEQUATE RETENTION OF THE DAMPER. IF THE DAMPER BECOMES LOOSE, FUEL COULD BE PUMPED BY THE FUEL PUMP INTO THE UNDER HOOD AREA.

Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.

Remedy: CHEVROLET AND WORKHORSE ARE HANDLING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN (PLEASE SEE 06V225 AND 06V289). DEALERS WILL REPLACE THE FUEL RAIL PULSE DAMPER RETAINER CLIPS ON THESE ENGINES FREE OF CHARGE. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, WORKHORSE AT 877-294-6773, OR DAMON AT 1-574-264-5517.

Reported: 2007-01-30 (January 30, 2007)

CERTAIN MOTOR HOMES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE MOTOR HOMES WERE BUILT WITHOUT THE RED REAR REFLEX REFLECTORS AND SOME MOTOR HOMES WERE BUILT WITHOUT THE SIDE REAR RED REFLEX REFLECTORS.

Consequence: DURING NIGHT DRIVING CONDITIONS OR WHILE THE MOTOR HOME IS PARKED, THE REAR AND SIDE MARKER LIGHTS WILL NOT PROVIDE ANY REFLEX REFLECTION TO MARK THE VEHICLE'S LOCATION IN THE DARK INCREASING THE RISK OF A CRASH.

Remedy: DAMON WILL PROVIDE THE OWNERS WITH A KIT CONTAINING THE MISSING REFLECTORS AND INSTRUCTIONS FOR APPLYING THEM TO THEIR VEHICLE. OWNERS MAY CHOOSE TO HAVE THEIR DEALERS DO THE REPAIR FREE OF CHARGE. THE RECALL BEGAN ON JULY 9, 2007. OWNERS MAY CONTACT DAMON AT 1-800-860-3812.

Reported: 2008-10-09 (October 9, 2008)

DAMON IS RECALLING 4,677 MY 2004-2006 CHALLENGER, DAYBREAK, INTRUDER, MY 2004-2005 ESCAPER, ULTRASPORT, AND MY 2005 ASTORIA AND ASTORIA WALDORF MOTOR HOMES EQUIPPED WITH A TWO-DOOR REFRIGERATOR MANUFACTURED BY THE DOMETIC CORPORATION. THE REFRIGERATOR 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 08E032). 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 THE OWNER 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

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.

Reported: 2010-09-09 (September 9, 2010)

DAMON IS RECALLING CERTAIN MODEL YEAR 2007-2011 CHALLENGER, MODEL YEAR 2005-2007 INTRUDER MOTOR HOMES. THESE MOTOR HOMES DO NOT HAVE THE PROPER CLEARANCE BETWEEN THE REAR SUSPENSION LEAF SPRING AND THE VEHICLE LIQUID PROPANE FUEL TANK. AS THE SUSPENSION TRAVELS IT IS POSSIBLE FOR THE LEAF SPRING SHACKLE BOLT TO COME IN CONTACT WITH THE TANK. THIS POTENTIALLY COULD PUNCTURE THE TANK AND RESULT IN A FIRE OR EXPLOSION.

Consequence: IN THE EVENT OF A FIRE OR EXPLOSION, THERE IS A POTENTIAL FOR PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Remedy: DAMON WILL INSPECT TO SEE IF THE PROPER CLEARANCE BETWEEN THE SHACKLE BOLT AND THE TANK EXISTS. IF IT IS FOUND THERE IS NOT ENOUGH CLEARANCE, THE TANK WILL BE RELOCATED TO PROVIDE THE PROPER CLEARANCE. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 6, 2010. OWNERS MAY CONTACT DAMON WARRANTY SERVICE DEPARTMENT AT 877-855-2867.