2005 Gulf Stream Sun Voyager Recalls

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NHTSA Campaign Number: 10V584000
Manufacturer: GULF STREAM COACH, INC.
Date of Owner Notification: March 23rd, 2011

Defect Summary:
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.

Consequence Summary:
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.

Corrective Summary:
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.

Recall 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 HTTP://WWW.SAFERCAR.GOV .

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NHTSA Campaign Number: 09V245000
Manufacturer: GULF STREAM COACH, INC.
Manufactured Begin Date: June 6th, 2002
Manufactured End Date: June 11th, 2007
Date of Owner Notification: May 1st, 2009

Defect Summary:
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.

Consequence Summary:
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.

Corrective Summary:
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

Recall 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 HTTP://WWW.SAFERCAR.GOV .

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NHTSA Campaign Number: 08V411000
Manufacturer: GULF STREAM COACH, INC.
Manufactured Begin Date: June 1st, 2003
Manufactured End Date: October 31st, 2006
Date of Owner Notification: October 31st, 2008

Defect Summary:
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.

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

Corrective Summary:
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.

Recall 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.

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NHTSA Campaign Number: 06V113000
Manufacturer: GULF STREAM COACH, INC.
Manufactured Begin Date: August 26th, 2002
Manufactured End Date: March 4th, 2005

Defect Summary:
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.

Consequence Summary:
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.

Corrective Summary:
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.

Recall 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.

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NHTSA Campaign Number: 04V380000
Manufacturer: GULF STREAM COACH, INC.
Manufactured Begin Date: April 15th, 2004
Manufactured End Date: June 24th, 2004

Defect Summary:
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.

Consequence Summary:
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.

Corrective Summary:
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.

Recall 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).