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.
The worst 2004 Damon Challenger problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Visibility2
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Visibility2
Recalls 5
Service brakes, hydraulic
- What is wrong
- 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.
- 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.
- 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.
Recall number 09V225000 · Recall details
Equipment: recreational vehicle/trailer
- What is wrong
- 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.
- Risk
- Release of coolant under certain conditions could ignite and result in a fire.
- 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
Recall number 08V534000 · Recall details
Equipment: recreational vehicle/trailer
- What is wrong
- 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.
- Risk
- Release of coolant under certain conditions could ignite and result in a fire.
- Remedy
- 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.
Recall number 07V130000 · Recall details
Engine and engine cooling
- What is wrong
- 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.
- Risk
- In the presence of an ignition source, a fire could result.
- 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.
Recall number 06V451000 · Recall details
Electrical system: instrument cluster/panel
- What is wrong
- 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.
- 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.
- 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.
Recall number 06V132000 · Recall details
What 2004 Damon Challenger owners say
Most recent owner complaints, unedited.
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 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
Compare the 2004 Damon Challenger
Other model years
1991199419961997199819992000200120022003200420052006200720082011
Questions about the 2004 Damon Challenger
Is the 2004 Damon Challenger reliable?
Owners have filed 2 complaints about the 2004 Damon Challenger, close to a typical Challenger model year.
What is the most common problem with the 2004 Damon Challenger?
Windows, wipers and visibility, with 2 complaints.
How many recalls does the 2004 Damon Challenger have?
5 recalls, covering service brakes, hydraulic, equipment and engine and engine cooling.
VIN decoder
See the problems and recalls for an exact car
Buying a used 2004 Damon Challenger?
Check the exact car before you pay: accidents, salvage or flood titles, odometer readings and previous owners.
Check its history