2004 Gulf Stream Sun Voyager

Defect. 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.

Risk. 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.

Defect. 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.

Risk. 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

Defect. 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.

Risk. 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.

Defect. 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.

Risk. 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.

Defect. ON CERTAIN MOTOR HOMES BUILT WITH DEWALT/POWER GEAR HYDRAULIC HOSES USED FOR THE SLIDE-OUT ROOMS AND LEVELING JACKS, THE CRIMPING PROCESS FOR ATTACHING THE HOSE FITTING TO THE END OF THE HYDRAULIC HOSE WAS PERFORMED IMPROPERLY.

Risk. WHEN ONE OF THE IMPROPERLY CRIMPED HOSE ASSEMBLIES IS PLACED UNDER A HEAVY LOAD, HYDRAULIC FLUID COULD BE RELEASED IN A HIGH PRESSURE SPRAY CREATING A RISK OF FIRE.

Remedy. DEWALT/POWER GEAR WILL NOTIFY GULF STREAM CUSTOMERS AND WILL INSPECT AND REPLACE THE HOSE FITTING. OWNERS SHOULD CONTACT GULF STREAM COACH AT 800-289-8787.

TL* THE CONTACT OWNS A 2004 GULF STREAM SUN VOYAGER RV. THE CONTACT STATED WHILE DRIVING 40 MPH, THERE WAS AN ABNORMAL ODOR OF BURNING RUBBER FROM THE BRAKES. THE CONTACT PULLED OVER AND NOTICE THE BRAKE CALIPER ON THE FRONT PASSENGER SIDE WAS LOCKED. THE CONTACT TOOK THE VEHICLE TO A DEALER TO HAVE THE CALIPERS, BRAKE PADS AND WHEEL BEARINGS REPLACED. AFTER THE REPAIR, THE CONTACT RECEIVED NOTIFICATION OF NHTSA RECALL CAMPAIGN ID NUMBER: 09V245000(SERVICE BRAKES, HYDRAULIC). THE CONTACT CALLED THE MANUFACTURER REGARDING REIMBURSEMENT AND THE MANUFACTURER DENIED THE CONTACT'S REQUEST. THE CONTACT STATED THAT THE MANUFACTURER SHOULD REIMBURSE THE OWNERS FOR THE COST OF THE REPAIRS TO THE BRAKING SYSTEM. THE FAILURE MILEAGE WAS 19,000.

TL*THE CONTACT OWNS A 2004 GULFSTREAM SUN VOYAGER WITH A WORKHORSE CHASSIS. THE CONTACT RECEIVED A RECALL NOTICE FROM THE CHASSIS MANUFACTURER IN MAY 2009 REGARDING RECALL 09V245000 (SERVICE BRAKES, HYDRAULIC). THE VEHICLE HAD NOT BEEN REPAIRED ACCORDING TO THE RECALL AT THE TIME THE COMPLAINT WAS FILED. WHEN HE CALLED THE MANUFACTURER, HE WAS INFORMED THAT THE PART WAS UNAVAILABLE. THE VIN WAS UNAVAILABLE AT THE TIME OF THE COMPLAINT. THE CURRENT AND FAILURE MILEAGES WERE UNKNOWN.

ON 7/15/2009 AFTER LEAVING LIMA, MT ON OUR WAY TO BASIN MT, I NOTICED BRAKES SEEMED TO BE GRABBING, SO MADE SURE TO DOWNSHIFT ON ALL HILLS. AS WE PULLED INTO CAMPGROUND AT BASIN, HEARD METAL TO METAL ON BRAKES. ASSUMING NEW BRAKE PADS NEEDED, ORDERED THEM FROM NEAREST WORKHORSE DEALER IN GREAT FALLS, MT, DROVE 130 MILES; PAID FOR THEM AND RETURNED. PULLED FRONT LEFT WHEEL & DISCOVERED ROTOR WAS CRACKED ON OUTBOARD ROTOR SURFACE. PULLED FRONT RIGHT WHEEL AND FOUND ROTOR CRACKED IN TWO PLACES ON OUTSIDE SURFACE. CALLED WORKHORSE DEALER IN GREAT FALLS AND WAS TOLD TO TAKE PICTURES OF ALL FOUR ROTORS, E-MAIL TO THEM AND THEY WOULD SEND ON TO WORKHORSE. LOOKED UP RECALL 50901-C ON INTERNET RECALLING ALL MODELS W22 SERIES RV CHASSIS, 7/24/2000 THROUGH 12/19/2007. AFTER WORKHORSE (CHRIS EGAN) HEADQUARTERS REC'D PICTURES, SAID WE HAD TO TAKE TO GF AND HAVE DEALER TAKE THE SAME PICTURES. WE DID THAT. THEN WORKHORSE SAID WILL NOT COVER COSTS. THEIR RECALL IS ON A PISTON STICKING AND OVERHEATING. OUR COMPLAINT IS THE CALIPERS STICKING IN THE RAILS AND DRAGGING ON THE OUTBOARD SIDE OF ROTORS. IF IT HAPPENS ON ALL FOUR WHEELS (REAR ROTORS HAD THREE AND FOUR CRACKS ON OUTBOARD SIDES) IT IS A MANUFACTURING DEFECT, AND SHOULD ALSO BE RECALLED. I AM A RETIRED MASTER MECHANIC AND HAVE NEVER SEEN ALL FOUR ROTORS CRACKED ON ANY VEHICLE. WHEN I ROTATED THE TIRES APRIL 2009 IN YUMA AZ, SAW NO CRACKS IN FRONT ROTORS; CHECKED BRAKE FLUID AND IT WAS NOT LOW. AT 3907 MILES LATER, (TRIP ODOMETER) ALL F

1. THE 1157 TAILLIGHT BULBS GENERATE ENOUGH HEAT TO MELT THE TAIL LIGHT HOUSING ASSEMBLY AND THE BULB FALLS OUT RESULTING IN NO TAIL LIGHTS, TURN SIGNALS, OR BRAKE LIGHTS. 2. NO TAIL LIGHTS, TURN SIGNALS, OR BRAKE LIGHTS. HAS OCCURRED ON BOTH SIDES. 3. TEMPORARILY TAPED THE BULB HOLDER INTO THE HOUSING TO PREVENT IT FROM FALLING OUT UNTIL COULD REACH DESTINATION. FAILED PARTS ARE AVAILABLE. *TR

2004 GULFSTREAM SUNVOYAGER WITH ENGINE OR TRANSMISSION ISSUES. MECHANIC TOLD THE CONSUMER THAT THEY WOULD NEED TO HAVE THE REAR CALIPERS, BRAKE PADS, TURN ROTORS, AND NEW ABS SENSORS AND WORKHORSE WILL NOT COVER ANY OF IT. *KB THE CONSUMER STATED NOTICED MOTORHOME WOULD NOT PICK UP SPEED AND THOUGHT THERE WERE ENGINE OR TRANSMISSION PROBLEMS UNTIL FURTHER INVESTIGATED BY THE CONSUMER AND STATED THERE WAS A STRONG BRAKE SMELL. THE CONSUMER WAS INFORMED THE PROBLEM WAS DUE TO RUST, HOWEVER THE CONSUMER DISAGREED WITH THE DEALERS FINDINGS AND AFTER TALKING WITH THE MANUFACTURER, THEY DECIDED TO COVER THE COST OF THE REPAIRS. *TR

MY 2004 GULF STREAM MOTOR VEHICLE PURCHASED NEW FROM LA MESA RV HAS A WATER HEATER INSTALLED WITHOUT AN ACCESS PANEL. GULF STREAM INSISTS THAT THIS IS NOT THEIR RESPONSIBILITY. THE MFG., SUBURBAN INSTALLATION INSTRUCTIONS SPECIFY AN ACCESS. GULF STREAM SAYS IT IS NECESSARY TO PULL THE WATER HEATER FOR ACCESS. TWO DIFFERENT REPAIR FACILITIES WHICH I HAVE VISITED ALSO THINK THIS IS A SERIOUS ERROR ON GULF STREAMS PART. *JB

MY VEHICLE HAS A WINDSHEILD LEAK THAT ALLOWS WATER TO RUN DOWN THE INSIDE OF THE WINDSHIELD WHEN IN RAINY CONDITIONS. THIS CONDITION BLURS AND OBSTRUCTS VISION IN THE VEHICLE. THE MANUFACTURER HAS ATTEMPTED REPAIR BUT THE PROBLEM PERSISTS. I HAVE DISCOVERED THAT MOST OF THESE VEHICLES HAVE THE SAME PROBLEM.

FRONT END BOUNCES WHEN GOING OVER BUMPS; 740 POUNDS TOO HEAVEY ON REAR AXLE, AND 5 FEET TOO LONG ON THE REAR AXLE. GULFSTREAM WILL NOT RETURN CALLS, WORKHORSE SAID IT WAS NOT THEIR PROBLEM. DEALER HAS HAD MOTORHOME FOR A MONTH.*AK *TT

WHILE DRIVING IN A RAIN STORM, THE WINDSHIELD WIPERS QUIT WORKING WITHOUT WARNING, WHICH RESULTED IN POOR VISIBILITY. THE DEALERSHIP WAS CONTACTED, THEY TOLD THE CONSUMER TO REPLACED THE FUSE. THE FUSE BLEW WHEN IT WAS REPLACED. THE VEHICLE WAS THEN TAKEN TO THE DEALERSHIP WHO INDICATED AFTER AN INSPECTION, THAT THE CIRCUIT BOARD WAS BAD. THE CIRCUIT BOARD WAS REPLACED, BUT THE PROBLEM RECURRED. *JB