NHTSA vehicle safety data

2005 Gulf Stream Sun Voyager Recalls & Complaints

The 2005 Gulf Stream Sun Voyager has 5 NHTSA recall campaigns and 3 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Gulf Stream dealer.

NHTSA recall and complaint data for the 2005 Gulf Stream Sun Voyager. Recall data is refreshed daily from NHTSA.

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

2005 Gulf Stream Sun Voyager owner complaints

Owners have filed 3 complaints with NHTSA about the 2005 Gulf Stream Sun Voyager, describing incidents dated May 21, 2005 to March 18, 2011.

Most-cited components

Fuel/Propulsion System 1 complaint
Parking Brake 1 complaint
Visibility/Wiper 1 complaint

Newest complaints

ODI #10407696 · Filed June 21, 2011
ON 3/18/2011 WHILE TRAVELING ON US-65 AT A SPEED OF APPROXIMATELY 65 MPH, WITHOUT WARNING THE AUTO PARK BRAKE APPLIED ON OUR GULF STREAM COACH. THE PANEL RED LIGHT STARTING BLINKING AND A LOUD BEEPING NOISE ALSO. WE EXITED THE HIGHWAY VERY STARTLED, NOT KNOWING IF WE COULD STOP OUR COACH. WE NOTICED…
ODI #10256150 · Filed January 23, 2009
I KEEP GETTING LIFE THREATENING RECALLS ON MY MOTORHOMES 3 SO FAR WHY SHOULDN'T MY DEALER BE REQUIRED TO TAKE THIS VEHICLE BACK I DON'T WANT MY FAMILY TO BURN ALIVE! *TR
ODI #10158066 · Filed May 23, 2006
[XXX]. 2005 GULFSTREAM SUN VOYAGER 8377 MOTOR HOME PASSENGER SIDE VIEW MIRROR COVER (BLACK PLASTIC, MEASURING 18" LONG BY 8" HIGH BY 6" WIDE AND WEIGHING 27 OUNCES) FELL OFF WHILE DRIVING. INSPECTION OF THE PART REVEALED THE PLASTIC FRACTURED AT ITS TWO ATTACHMENT POINTS DUE TO NORMAL AIR PRESSURE…

Read all 3 complaints

REFRIGERATORS/POSSIBLE FIRE

NHTSA #10V584000 · Equipment — Recreational Vehicle/Trailer · NHTSA notice

Reported November 22, 2010 · GULF STREAM COACH, INC.

Potentially affected: 1,328 vehicles

Owners notified March 23, 2011

Defect description

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.

Safety 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.

Manufacturer 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.

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> .

OVERHEATED BRAKE CALIPERS/BOSCH/WORKHORSE

NHTSA #09V245000 · Service Brakes, Hydraulic · NHTSA notice

Reported July 1, 2009 · GULF STREAM COACH, INC.

Potentially affected: 15 vehicles

Owners notified May 1, 2009 · Vehicles built June 6, 2002 – June 11, 2007 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

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

REFRIGERATOR/DOMETIC

NHTSA #08V411000 · Equipment — Recreational Vehicle/Trailer · NHTSA notice

Reported August 15, 2008 · GULF STREAM COACH, INC.

Potentially affected: 26,847 vehicles

Owners notified October 31, 2008 · Vehicles built June 1, 2003 – October 31, 2006 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety consequence

IF THIS SOLUTION IS EXPOSED TO AN IGNITION SOURCE UNDER CERTAIN SPECIFIC CIRCUMSTANCES, IT CAN RESULT IN A VEHICLE FIRE.

Manufacturer 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.

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.

INSTRUMENT CLUSTER/FMVSS 101 AND 105/WORKHORSE

NHTSA #06V113000 · Electrical System · NHTSA notice

Reported April 11, 2006 · GULF STREAM COACH, INC.

Potentially affected: 995 vehicles

Vehicles built August 26, 2002 – March 4, 2005 (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 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.

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

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.

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.

GULF STREAM/DEWALT/POWER GEAR HYDRAULIC HOSE

NHTSA #04V380000 · Equipment — Recreational Vehicle/Trailer · NHTSA notice

Reported August 3, 2004 · GULF STREAM COACH, INC.

Potentially affected: 104 vehicles

Vehicles built April 15, 2004 – June 24, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer 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.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

try.vin has no NCAP crash-test rating on file for the 2005 Gulf Stream Sun Voyager. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

3 owner complaints have been filed with NHTSA for the 2005 Gulf Stream Sun Voyager.

Parking Brake

ODI #10407696

Incident: March 18, 2011 · Filed: June 21, 2011

ON 3/18/2011 WHILE TRAVELING ON US-65 AT A SPEED OF APPROXIMATELY 65 MPH, WITHOUT WARNING THE AUTO PARK BRAKE APPLIED ON OUR GULF STREAM COACH. THE PANEL RED LIGHT STARTING BLINKING AND A LOUD BEEPING NOISE ALSO. WE EXITED THE HIGHWAY VERY STARTLED, NOT KNOWING IF WE COULD STOP OUR COACH. WE NOTICED A BURNING SMELL AND I INVESTIGATED. AFTER CONFIRMING WE HAD SERVICE BRAKES, CALLED WORKHORSE (WCC) FACILITY AND WAS TOLD THAT AUTO PARK BRAKE AND SERVICE BRAKES WERE ON 2 SEPARATE SYSTEMS AND SHOULD BE OK TO DRIVE HOME 300 MILES. BUT WE HAD NO PARK BRAKE ON OUR COACH, HAD TO BLOCK WHEELS WHEN PARKED. UPON TAKING RV TO AUTHORIZED WCC SERVICE CENTER IN TOLEDO OHIO WAS TOLD THAT PARKING BRAKE ASSEMBLY # W8001667 OVERHEATED WHEN IT SUDDENLY APPLIED AT HIGHWAY SPEED (FOR NO REASON) AND HAD TO BE REPLACED (COST OF APPROX. $2,300). THEY AND THE WCC DISTRICT REP WHO I SPOKE WITH HAD NO EXPLANATION WHY THIS HAPPENED. AND COULD NOT ASSURE ME THAT IT WOULD NOT HAPPEN AGAIN. THIS OCCURRED AT APPROXIMATELY 13,700 MILES ON OUR 2005 GULF STREAM COACH W24 CHASSIS EQUIPPED WITH J72 PARK BRAKE SYSTEM. AFTER SEVERAL SEARCHES ONLINE, I.E. IRV2.COM A SITE WHERE NUMEROUS RV OWNERS WITH WCC CHASSIS EXPRESSED AND DISCUSSED THEIR EXPERIENCES WITH SIMILAR CONCERNS AND FEARS. I COULD NOT BELIEVE ALL THE HISTORY OF THESE PROBLEMS THAT SO MANY PEOPLE HAD AND MOST CONSULTED WCC AND NHTSA. SOME OF WHICH WHEN THIS HAPPENED PUT THEIR FAMILY AND OTHERS IN DANGER. I AM QUITE FRANKLY CONCERNED AND WORRIED THAT THIS COULD HAPPEN AGAIN (WHEN PLANNING OUR NEXT RV TRIP). AFTER DISCUSSING PROBLEM AND LARGE EXPENSE WITH THE DISTRICT REP, WE WERE NOT HELPED WITH REPAIR COST OR COMFORTED KNOWING WHY THIS HAPPENED OR IF IT COULD HAPPEN AGAIN PUTTING LIVES IN DANGER. SMITTY'S AUTOMOTIVE SERVICE IN TOLEDO OHIO IS THE AUTHORIZED WCC SERVICE FACILITY OF MY CHOICE WHICH I HAVE HIGH REGARDS AND COMPLETE CONFIDENCE. I AM REPORTING THIS B/C I'M CONCERNED AND WORRIED THAT THIS COULD HAPPEN AGAIN. *TR

Fuel System, Gasoline

ODI #10256150

Incident: January 23, 2009 · Filed: January 23, 2009

I KEEP GETTING LIFE THREATENING RECALLS ON MY MOTORHOMES 3 SO FAR WHY SHOULDN'T MY DEALER BE REQUIRED TO TAKE THIS VEHICLE BACK I DON'T WANT MY FAMILY TO BURN ALIVE! *TR

Visibility

ODI #10158066

Incident: May 21, 2005 · Filed: May 23, 2006

[XXX]. 2005 GULFSTREAM SUN VOYAGER 8377 MOTOR HOME PASSENGER SIDE VIEW MIRROR COVER (BLACK PLASTIC, MEASURING 18" LONG BY 8" HIGH BY 6" WIDE AND WEIGHING 27 OUNCES) FELL OFF WHILE DRIVING. INSPECTION OF THE PART REVEALED THE PLASTIC FRACTURED AT ITS TWO ATTACHMENT POINTS DUE TO NORMAL AIR PRESSURE WHILE DRIVING. THE SIDE VIEW MIRROR ARMS AND COVERS ON BOTH SIDES OF THE MOTOR HOME SHAKE A LOT IN THE WIND DURING NORMAL DRIVING. INSPECTION OF THE DRIVER'S SIDE MIRROR COVER REVEALED PARTIAL PLASTIC FRACTURES AT THE SAME TWO ATTACHMENT POINTS, SO I REMOVED THE COVER TO AVOID ITS FALLING OFF. IF THIS FAILURE WERE TO OCCUR WHILE DRIVING ON A MULTI-LANE HIGHWAY THE LARGE MIRROR COVER COULD HEAD AT THE WINDSHIELD OF AN ADJACENT VEHICLE, PERHAPS CAUSING THE DRIVER TO SWERVE AND LOOSE CONTROL OF THE VEHICLE. I WAS ON A TWO LANE ROAD WHEN THE MIRROR COVER FELL OFF, SO IT LANDED IN THE GRASS ALONGSIDE THE ROAD. I HAVE DETAILED DIGITAL PHOTOS OF THE FAILED PART AND ITS ATTACHMENT STRUCTURE, AS WELL AS THE PART. *NM UPDATED 07/16/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Other Gulf Stream Sun Voyager model years

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