2003 Gulf Stream SUN VOYAGER: complaints, problems and recalls

ABS LIGHT INDICATOR FLASHES THEN IT STAYS ON. DEALER HAS KEPT THE MOTOR HOME FROM SEPTEMBER 11, UNTIL TODAY, BUT CAN'T REPRODUCE OR FIX THE PROBLEM. *AK

Owner-reported narrative. 7,200 miles reported. Look up ODI 10048125 at NHTSA ↗

2003 GULF STREAM MH SUNVOYAGER 36FT. 5000LB RECEIVER RIPPED LOOSE FROM EXTENSION OF WORKHORSE W22 CHASSIS 125 MI SO OF FORT NELSON,BC ON 7/1/05. TOWING A 2004 HONDA CRV(3400LBS). EXTENSION FRAMING RIPPED ON LEFT SIDE LIKE A PIECE OF PAPER AND PARTIALLY RIPPED ON RIGHT SIDE. CRV WAS NEARLY COMPLETELY SEPARATED FROM TOW VEHICLE. BREAKAWAY SYSTEM WOULD BE USELESS BECAUSE IT WAS TIED TO RECEIVER. ONLY PURE LUCK KEPT US FROM A MAJOR ACCIDENT. ACCORDING TO WELD SHOP OWNER,THIS WAS HIS 4TH SUCH REPAIR IN PAST WEEK. MH MANUFACTURES SHOULD BE HELD…

Owner-reported narrative. Look up ODI 10137528 at NHTSA ↗

DT: THE CONTACT COMPLAINED ABOUT BRAKE FAILURE WHILE TRAVELING OUT OF TOWN. HE TOOK THE VEHICLE TO A SERVICE DEALER, WHO INFORMED HIM OF NHTSA CAMPAIGN 03V092000, CONCERNING SERVICE BRAKES, HYDRAULIC:SWITCHES:BRAKE WARNING. . THE DEALER WAS ONLY ABLE TO OFFER A TEMPORARY REPAIR BECAUSE OF PARTS AVAILABILITY. THE CONTACT TOOK VEHICLE TO LOCAL SERVICE DEALER, AND WAS AWAITING A COMPLETE BRAKE REPAIR. HIS PRIMARY CONCERN WAS THAT HE DID NOT RECEIVE A RECALL NOTICE BY MAIL.*AK

Owner-reported narrative. 22,600 miles reported. Look up ODI 10144583 at NHTSA ↗

CUSTOMER STATES THAT THEY HAD TO PAY OUT OF POCKET FOR RECALL REPAIR AND IS ASKING FOR ADVICE TO GET REIMBURSEMENT FROM DOMETIC**CC THE CONSUMER STATED IN HIS OPINION, THE KIT FOR THE RECALL WAS NOT A CORRECTION FOR THE DEFECT, IT WAS MERELY PUTTING A METAL BOX AROUND THE DANGER AREA WITH A THERMO-COUPLER TO TURN OFF THE GAS IF IT STARTS A FIRE. THE CONSUMER WAS INFORMED THAT HE WOULD BE RESPONSIBLE FOR SOME OF THE LABOR BECAUSE THE MANUFACTURER WOULD ONLY PAY $40.00 AND THE SHOP CHARGED $95 PER HOUR FOR LABOR, SO THERFORE IF IT TOOK MORE THA…

Owner-reported narrative. Look up ODI 10191099 at NHTSA ↗

TL*THE CONTACT OWNS A 2003 GULF STREAM SUN VOYAGER. WHILE DRIVING 40 MPH, THE VEHICLE WOULD NOT ACCELERATE. WHEN THE VEHICLE WOULD COAST, IT BEGAN TO STOP AUTOMATICALLY AND MORE QUICKLY THAN USUAL. WHEN THE CONTACT EXAMINED THE VEHICLE, HE NOTICED THAT THE REAR DRIVER SIDE TIRES WERE EXTREMELY HOT AND THE ABS WARNING LIGHT ILLUMINATED. THE CONTACT DID NOT NOTICE ANY DIFFERENCES IN THE VEHICLE PRIOR TO THE FAILURE. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT MILEAGE WAS 17,447 AND FAILURE MILEAGE WAS 13,700.

Owner-reported narrative. 13,700 miles reported. Look up ODI 10232142 at NHTSA ↗

TL* THE CONTACT OWNS A 2003 GULFSTREAM SUNVOYAGER. DURING BRAKE APPLICATION WHILE DRIVING DOWNHILL AT 40 MPH THE BRAKE PEDAL WENT TO THE FLOOR. AFTER REPEATED BRAKE APPLICATION HE WAS ABLE TO STOP. AFTER AN HOUR OF WAITING HE NOTICED HEAT BUILD-UP IN THE BRAKE SYSTEM. A MECHANIC INSPECTED THE VEHICLE, AND MADE A TEMPORARY REPAIRS. HE WAS ADVISED THAT HIS VEHICLE IDENTIFICATION NUMBER WAS EXCLUDED FROM RECALL 09V245000 (SERVICE BRAKES, HYDRAULIC). HE WAS INELIGIBLE FOR A FREE REMEDY, SO NO REPAIRS WERE MADE. THE FAILURE MILEAGE WAS 30000 . …

Owner-reported narrative. 30,000 miles reported. Look up ODI 10295786 at NHTSA ↗

Reported: 2003-03-12 (March 12, 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 1, 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 GULF STREAM AT 1-574-773-7761.

Reported: 2003-09-03 (September 3, 2003)

ON CERTAIN MOTOR HOMES BUILT ON THE WORKHORSE W22 CHASSIS, THE DROP DOWN BRACKETS USED TO ATTACH THE HITCH TO THE FRAME RAIL EXTENSIONS MAY NOT BE ADEQUATE.

Consequence: IN THE EVENT THAT THESE ANGLE BRACKETS WOULD FAIL, THE HITCH AND THE TOW VEHICLE COULD BECOME DISLODGED FROM THE MOTOR HOME INCREASING THE RISK OF A CRASH.

Remedy: GULF STREAM HAS DEVELOPED A REPAIR KIT CONSISTING OF STEEL BRACKETS, SPACERS, AND MECHANICAL FASTENERS. THIS KIT CAN BE SENT DIRECTLY TO YOU OR TO A REPAIR FACILITY OF YOUR CHOOSING. OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING SEPTEMBER 2003. OWNERS SHOULD CONTACT GULF STREAM AT 1-800-482-6456, EXT. 3743.

Reported: 2006-04-11 (April 11, 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 NOS. 101 "CONTROLS AND DISPLAYS" AND 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: WORKHORSE IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN AND REPROGRAM THE INSTRUMENT PANEL CLUSTER FREE OF CHARGE. OWNERS MAY CONTACT WORKHORSE AT 1-877-246-7731 OR GULF STREAM AT 574-773-7761.

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

CERTAIN MOTOR HOMES, FIFTH WHEEL AND TRAVEL TRAILERS 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: GULF STREAM 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. THE RECALL BEGAN ON JUNE 28, 2007. OWNERS MAY CONTACT DOMETIC/STERICYCLE AT 1-888-446-5157 OR GULF STREAM AT 1-574-773-7761.

Reported: 2008-08-15 (August 15, 2008)

GULF STREAM IS RECALLING 26,847 MY 2003-2006 RECREATIONAL VEHICLES 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: IF THIS SOLUTION IS EXPOSED TO AN IGNITION SOURCE UNDER CERTAIN SPECIFIC CIRCUMSTANCES, IT CAN RESULT IN A VEHICLE FIRE.

Remedy: GULF STREAM IS WORKING WITH DOMETIC 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 GULF STREAM AT 1-574-773-7761.

Reported: 2009-07-01 (July 1, 2009)

GULF STREAM IS RECALLING 15 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: 2009-10-01 (October 1, 2009)

GULF STREAM IS RECALLING CERTAIN MOTORHOMES EQUIPPED WITH NORCOLD MODEL 1200LR, 1200LRIM, AND 1201LRIM REFRIGERATORS WITH SERIAL NUMBERS BETWEEN 1273701 AND 1536607, NON-CONSECUTIVELY. A FATIGUE FAILURE IN THE SECTION OF THE COOLING UNIT WHICH CONTAINS THE REFRIGERANT COULD ALLOW THE LIQUID SOLUTION TO SLOWLY LEAK. IF A LEAK OCCURS AND THE REFRIGERATOR CONTINUES TO BE OPERATED AFTER SOLUTION CIRCULATION HAS CEASED THE HEAT SOURCE COULD GENERATE VERY HIGH TEMPERATURES. AT SUCH HIGH TEMPERATURES, THE COOLING UNIT COULD RUPTURE.

Consequence: IF A LEAK OCCURS AND THE UNIT CONTINUES TO OPERATE, HYDROGEN GAS MAY BE EXPELLED AND CAN BE IGNITED, RESULTING IN A FIRE, POSSIBLY CAUSING SERIOUS INJURY OR DEATH.

Remedy: GULF STREAM IS WORKING WITH NORCOLD AND THE VEHICLE'S REFRIGERATOR WILL BE REPAIRED FREE OF CHARGE. PLEASE ALSO SEE NORCOLD'S DEFECT NOTICE 09E-027. THE SAFETY RECALL BEGAN ON OCTOBER 20, 2009. OWNERS MAY CONTACT GULF STREAM AT 1-800-289-8787 OR NORCOLD'S RECALL CENTER AT 1-800-767-9101.

Reported: 2010-11-22 (November 22, 2010)

GULF STREAM IS RECALLING CERTAIN RECREATIONAL VEHICLES AND FIFTH WHEEL TRAILERS EQUIPPED WITH 1200-SERIES NORCOLD REFRIGERATORS. THE POPULATION OF REFRIGERATORS BEING ADDRESSED CONTAINS EITHER A SENSING ALGORITHM OR THERMAL SWITCH TO SHUT OFF POWER TO THE REFRIGERATOR WHEN HIGH TEMPERATURES ARE DETECTED IN ORDER TO PREVENT A POTENTIAL FIRE. THE RESPONSE TIMES OF THE SENSOR ALGORITHM AND THERMAL SWITCH DEVICES TO STOP POWER ARE NOT SUFFICIENT.

Consequence: THE SENSING ALGORITHM OR THERMAL SWITCH INSTALLED TO SHUT OFF POWER TO THE REFRIGERATOR WHEN HIGH TEMPERATURES ARE DETECTED DUE TO A POSSIBLE HYDROGEN GAS LEAK MAY NOT SHUT OFF IN SUFFICIENT TIME TO PREVENT A FIRE.

Remedy: GULF STREAM IS WORKING WITH NORCOLD TO IDENTIFY AND NOTIFY ANY AFFECTED OWNERS. OWNERS WILL BE INSTRUCTED TO CONTACT NORCOLD DEALERS TO RECEIVE THE REMEDY FREE OF CHARGE. PLEASE SEE NORCOLD'S DEFECT REPORT 10E-049 FOR ADDITIONAL INFORMATION. THE RECALL BEGAN ON MARCH 23, 2011. OWNERS MAY CONTACT NORCOLD AT 1-800-767-9101 OR GULF STREAM AT 1-574-773-7761.