- The problem
- 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.
- The 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.
- The fix
- 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.
Vehicle safety record
2004 Damon Challenger Problems, complaints & recalls
Owners have filed 2 complaints about the 2004 Damon Challenger with NHTSA, most often about the visibility & wipers (2). It is covered by 5 recalls, the latest in June 2009 for the service brakes, hydraulic. For comparison, the 2003 has 7 and the 2005 has 2.
NHTSA data checked
CAbout as many problems as a typical Challenger year, for its age
#364 most complained-about 2004 vehicle
- Complaints
- 2
- Recalls
- 5
- Crashes
- 0
- Fires
- 0
- Injuries
- 0
- Deaths
- 0
Most common 2004 Damon Challenger problems
Share of all 2 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.
2004 Damon Challenger recalls 5
Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do
- The problem
- 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.
- The risk
- Release of coolant under certain conditions could ignite and result in a fire.
- The fix
- 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
- The problem
- 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.
- The risk
- Release of coolant under certain conditions could ignite and result in a fire.
- The fix
- 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.
- The problem
- 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.
- The risk
- In the presence of an ignition source, a fire could result.
- The fix
- 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.
- The problem
- 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.
- The 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.
- The fix
- 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.
What owners say
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2 complaints about the 2004 Damon Challenger
Newest first, as filed with NHTSA by owners.
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.
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...
Read the full complaint
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
Damon Challenger: every year compared
All Challenger years2004 Damon Challenger vs rivals
| Vehicle | Complaints | Recalls | Grade | |
|---|---|---|---|---|
| 2004 Damon Challenger | 2 | 5 | C | |
| 2004 Damon Daybreak | 5 | 4 | D | Compare |
| 2004 Damon Intruder | 4 | 6 | D | Compare |
More sales usually means more complaints, so compare similar vehicles of the same year. The grade compares each vehicle with its own model's other years.
Questions about the 2004 Damon Challenger
Does the 2004 Damon Challenger have any recalls?
Yes - NHTSA lists 5 recalls for the 2004 Damon Challenger: service brakes, hydraulic (June 2009); recreational vehicle / trailer (October 2008); recreational vehicle / trailer (March 2007); engine and engine cooling (November 2006) and more. Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.
What are the most common problems with the 2004 Damon Challenger?
By the complaints owners filed with NHTSA, the most common problem areas are the visibility & wipers (2).
How many complaints has the 2004 Damon Challenger had?
2 complaints have been filed with NHTSA, the first on September 28, 2015 and the latest on January 11, 2016. Of these, 0 describe a crash and 0 a fire, and together they report 0 injuries and 0 deaths.
Is the 2004 Damon Challenger a reliable vehicle?
Its Safety Index is 45 out of 100 (grade C: about as many problems as a typical Damon Challenger year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.
Which Damon Challenger years have the most complaints?
2003 (7), 1998 (6), 1999 (6). See every Damon Challenger year compared.
What should I do if my 2004 Damon Challenger has a problem?
If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data