The 2004 Gulf Stream Sun Voyager has 5 NHTSA recall campaigns affecting an estimated 29,289 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 12 complaints with NHTSA, most often about the service brakes, hydraulic. Last updated July 5, 2026.
Recall campaigns
EQUIPMENT10V5840002010-11-221,328 affected
Defect
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…
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.
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…
SERVICE BRAKES, HYDRAULIC09V2450002009-07-0115 affected
Defect
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…
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.
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
EQUIPMENT08V4110002008-08-1526,847 affected
Defect
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
IF THIS SOLUTION IS EXPOSED TO AN IGNITION SOURCE UNDER CERTAIN SPECIFIC CIRCUMSTANCES, IT CAN RESULT IN A VEHICLE FIRE.
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…
ELECTRICAL SYSTEM06V1130002006-04-11995 affected
Defect
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,…
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.
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.
EQUIPMENT04V3800002004-08-03104 affected
Defect
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
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.
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.
Complaints by component
SERVICE BRAKES, HYDRAULIC
4
1fires
EQUIPMENT ADAPTIVE/MOBILITY
1
EQUIPMENT:RECREATIONAL VEHICLE/TRAILER
1
EXTERIOR LIGHTING
1
POWER TRAIN:AXLE ASSEMBLY
1
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
1
SUSPENSION:FRONT
1
VISIBILITY:WINDSHIELD
1
VISIBILITY:WINDSHIELD WIPER/WASHER
1
Total complaints12
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“On 7/15/2009 after leaving lima, mt on our way to basin mt, I noticed brakes seemed to be grabbing, so made sure to downshift on all hills. As we pulled into campground at basin, heard metal to metal on brakes. Assuming new brake pads needed, ordered them from nearest workhorse dealer in great…”
“Tl*the contact owns a 2004 gulfstream sun voyager with a workhorse chassis. The contact received a recall notice from the chassis manufacturer in may 2009 regarding recall 09v245000 (service brakes, hydraulic). The vehicle had not been repaired according to the recall at the time the complaint was…”
“Tl* the contact owns a 2004 gulf stream sun voyager rv. The contact stated while driving 40 mph, there was an abnormal odor of burning rubber from the brakes. The contact pulled over and notice the brake caliper on the front passenger side was locked. The contact took the vehicle to a dealer to…”
“1. The 1157 taillight bulbs generate enough heat to melt the tail light housing assembly and the bulb falls out resulting in no tail lights, turn signals, or brake lights. 2. No tail lights, turn signals, or brake lights. Has occurred on both sides. 3. Temporarily taped the bulb holder into the…”
“2004 gulfstream sunvoyager with engine or transmission issues. Mechanic told the consumer that they would need to have the rear calipers, brake pads, turn rotors, and new abs sensors and workhorse will not cover any of it. *kb the consumer stated noticed motorhome would not pick up speed and…”
“2004 gulfstream sunvoyager with engine or transmission issues. Mechanic told the consumer that they would need to have the rear calipers, brake pads, turn rotors, and new abs sensors and workhorse will not cover any of it. *kb the consumer stated noticed motorhome would not pick up speed and…”
“My 2004 gulf stream motor vehicle purchased new from la mesa rv has a water heater installed without an access panel. Gulf stream insists that this is not their responsibility. The mfg., suburban installation instructions specify an access. Gulf stream says it is necessary to pull the water heater…”
“My 2004 gulf stream motor vehicle purchased new from la mesa rv has a water heater installed without an access panel. Gulf stream insists that this is not their responsibility. The mfg., suburban installation instructions specify an access. Gulf stream says it is necessary to pull the water heater…”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Gulf Stream Sun Voyager as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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