NHTSA vehicle safety data

2004 Damon Challenger Recalls & Complaints

The 2004 Damon Challenger has 5 NHTSA recall campaigns and 2 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Damon dealer.

NHTSA recall and complaint data for the 2004 Damon Challenger. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Damon Challenger owner complaints

Owners have filed 2 complaints with NHTSA about the 2004 Damon Challenger, describing incidents dated September 12, 2014 to September 16, 2015.

Most-cited components

Visibility/Wiper 2 complaints

Newest complaints

ODI #10819380 · Filed January 11, 2016
THE DAMON MOTORHOME HAS A TWO PIECE WINDSHIELD THAT HAS AN INHERENT PROBLEM AS THE UNIT GET OLDER THE WINDSHIELD WILL UNEXPECTEDLY POP OUT OF THE RUBBER SEAL. IT SEEMS AS IF THE FLEXING OF THE FRONT CAP CAUSES THE WINDSHIELD TO POP OUT OF THE RUBBER SEAL AT THE TOP IN SOME CASES TO 1 INCH, 6-8…
ODI #10778009 · Filed September 28, 2015
WINDSHIELD POPPING OUT OF RUBBER GASKET WE BOUGHT THE 2004 DAMON MOTORHOME NEW AND HAVE HAD MANY PROBLEMS WITH WATER LEAKING AROUND THE WINDSHIELD RUBBER GASKET. IN THE LAST YEAR WE HAVE HAD THE WINDSHIELD POP OUT OF THE RUBBER GASKET CAUSING LARGE AMOUNTS OF WATER TO COME IN DURING RAIN STORMS. WE…

Read all 2 complaints

OVERHEATED BRAKE CALIPERS/BOSCH/WORKHORSE

NHTSA #09V225000 · Service Brakes, Hydraulic · NHTSA notice

Reported June 16, 2009 · DAMON CORPORATION

Potentially affected: 2,415 vehicles

Owners notified May 1, 2009 · Vehicles built January 1, 2001 – May 27, 2009 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

REFRIGERATOR/DOMETIC

NHTSA #08V534000 · Equipment — Recreational Vehicle/Trailer · NHTSA notice

Reported October 9, 2008 · DAMON CORPORATION

Potentially affected: 4,677 vehicles

Owners notified October 21, 2008 · Vehicles built May 1, 2003 – June 30, 2006 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety consequence

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

Manufacturer 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

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

REFRIGERATOR/DOMETIC

NHTSA #07V130000 · Equipment — Recreational Vehicle/Trailer · NHTSA notice

Reported March 20, 2007 · DAMON CORPORATION

Potentially affected: 25,128 vehicles

Owners notified June 26, 2007 · Vehicles built April 1, 1997 – April 30, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer 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.

Notes

CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

FUEL RAIL CLIP FRACTURE/CHEVROLET/WORKHORSE

NHTSA #06V451000 · Engine and Engine Cooling · NHTSA notice

Reported November 28, 2006 · DAMON CORPORATION

Potentially affected: 1,517 vehicles

Vehicles built May 13, 2003 – June 29, 2006 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer 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.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATIONS VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

INSTRUMENT CLUSTER/FMVSS 101 AND 105/WORKHORSE

NHTSA #06V132000 · Electrical System — Instrument Cluster/Panel · NHTSA notice

Reported April 24, 2006 · DAMON CORPORATION

Potentially affected: 1,705 vehicles

Vehicles built July 1, 2002 – May 31, 2004 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2004 Damon Challenger. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

2 owner complaints have been filed with NHTSA for the 2004 Damon Challenger.

Visibility/Wiper

ODI #10819380

Incident: September 12, 2014 · Filed: January 11, 2016

THE DAMON MOTORHOME HAS A TWO PIECE WINDSHIELD THAT HAS AN INHERENT PROBLEM AS THE UNIT GET OLDER THE WINDSHIELD WILL UNEXPECTEDLY POP OUT OF THE RUBBER SEAL. IT SEEMS AS IF THE FLEXING OF THE FRONT CAP CAUSES THE WINDSHIELD TO POP OUT OF THE RUBBER SEAL AT THE TOP IN SOME CASES TO 1 INCH, 6-8 INCHES IN LENGTH. THIS CREATES A PROBLEM WHEN YOU'RE DRIVING ALONG THE ROAD AND IT POPS OUT. IT ALLOWS WATER TO COME IN AND MAKE YOU WONDER IF THE ENTIRE WINDSHIELD WILL FALL OUT OR WORSE BLOW IN ON THE DRIVER AND PASSENGER. THE MANUFACTURER, THOR WILL NOT HONOR THE PROBLEM AND BLOW IT OFF. IT IS UNDERSTOOD THAT THIS IS A PROBLEM ON ALL MODELS WITH TWO PIECE WINDSHIELDS.

Visibility/Wiper

ODI #10778009

Incident: September 16, 2015 · Filed: September 28, 2015

WINDSHIELD POPPING OUT OF RUBBER GASKET WE BOUGHT THE 2004 DAMON MOTORHOME NEW AND HAVE HAD MANY PROBLEMS WITH WATER LEAKING AROUND THE WINDSHIELD RUBBER GASKET. IN THE LAST YEAR WE HAVE HAD THE WINDSHIELD POP OUT OF THE RUBBER GASKET CAUSING LARGE AMOUNTS OF WATER TO COME IN DURING RAIN STORMS. WE SEALED THE WINDSHIELD THE BEST WE COULD TO KEEP OUT THE RAIN BUT THE GLASS WAS COMING OUT FURTHER AND FURTHER. WE TOOK IT TO A DEALER AND THEY REMOVED THE WINDSHIELDS AND CLEANED THE RUBBER GASKET. AFTER A COUPLE OF DAYS USE THE WINDSHIELD POPPED OUT AGAIN ON THE TOP. THE DEALER THEN DECIDED THE COACH NEEDED A NEW RUBBER GASKET. THE DEALER THEN WENT REPLACED THE GASKET AND RE-INSTALLED THE WINDSHIELDS. AFTER A WEEK OF USE THE TOP OF THE GLASS WAS POPPED OUT OF THE NEW RUBBER GASKET. THE DEALER DOES NOT KNOW WHAT TO DO KNOW. THE DAMON COMPANY NOW THOR MOTOR COACH, PO BOX 1486 ELKHART, INDIANA 46515 SHOULD BE MAKING A RECALL TO FIX THIS PROBLEM. IT IS HAPPENING ON MANY OF THE OLDER DAMON MODELS FROM 2002 - 2009

Other Damon Challenger model years

Check your 2004 Damon Challenger VIN

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