NHTSA vehicle safety data

2005 Damon Intruder Recalls & Complaints

The 2005 Damon Intruder has 7 NHTSA recall campaigns and 4 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 2005 Damon Intruder. Recall data is refreshed daily from NHTSA.

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

2005 Damon Intruder owner complaints

Owners have filed 4 complaints with NHTSA about the 2005 Damon Intruder, describing incidents dated January 2, 2006 to January 15, 2012.

Most-cited components

Structure 2 complaints
Visibility/Wiper 2 complaints
Electrical System 1 complaint
Service Brakes 1 complaint

Newest complaints

ODI #10461971 · Filed June 16, 2012
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…
ODI #10388610 · Filed March 6, 2011
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…
ODI #10359096 · Filed October 4, 2010
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…

Read all 4 complaints

LP FUEL TANK

NHTSA #10V407000 · Equipment — Recreational Vehicle/Trailer — LPG Systems — Tank Assembly · NHTSA notice

Reported September 9, 2010 · THOR MOTOR COACH

Potentially affected: 271 vehicles

Manufacturer campaign RC000018 · Owners notified October 6, 2010 · Vehicles built April 16, 2004 – September 1, 2010 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer 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.

Notes

DAMON SAFETY RECALL NO. RC000018.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> .

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.

RED REAR REFLEX REFLECTORS/FMVSS 108

NHTSA #07V022000 · Exterior Lighting · NHTSA notice

Reported January 30, 2007 · DAMON CORPORATION

Potentially affected: 2,618 vehicles

Damon campaign 06-119 · Owners notified July 9, 2007

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

DAMON RECALL NO. 06-119.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.

STEERING INTERMEDIATE SHAFT/WORKHORSE

NHTSA #06V236000 · Steering · NHTSA notice

Reported June 30, 2006 · DAMON CORPORATION

Potentially affected: 116 vehicles

Vehicles built April 28, 2005 – March 15, 2006 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer 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.

Notes

CUSTOMERS CAN 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.

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 2005 Damon Intruder. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

4 owner complaints have been filed with NHTSA for the 2005 Damon Intruder.

Visibility; Structure

ODI #10461971

Incident: January 15, 2012 · Filed: June 16, 2012

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 THE FIBER GLASS AREA ON THE FRONT CAP TO MATCH THE CURVE & RADIUS OF THE WINDSHIELD. THE FRAME WORK ON THE LOWER FRAME SUPPORT HAD TO BE REPAIRED & RE-ATTACHED TO THE FRONT CAP, IN ORDER FOR THE WINDSHIELD TO SET & SEAL CORRECTLY. WE HAVE REPAIRED SEVERAL OF THESE UNITS THAT HAVE THE SAME MANUFACTURER DEFECT & PROBLEM WITH FRONT WINDSHIELDS. PLEASE FEEL FREE TO CONTACT ME WITH ANY QUESTIONS OR ANY ADDITIONAL INFORMATION THAT YOU MAY NEED. *JB

Service Brakes, Hydraulic

ODI #10388610

Incident: March 6, 2007 · Filed: March 6, 2011

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!!!

Visibility; Structure

ODI #10359096

Incident: September 27, 2010 · Filed: October 4, 2010

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.

Electrical System

ODI #10149751

Incident: January 2, 2006 · Filed: January 25, 2006

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

Other Damon Intruder model years

Check your 2005 Damon Intruder VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Damon Intruder at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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