Recalls
| Campaign | Manufacturer | Manufacturing date | Type | # of units affected | Date Owner notified Mfg | Recall Initiated by | Manufacturers of recalled vehicles/products | Report Recieved Date | Record Creation Date | Regulation Part Number | FMVSS Number | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| SERVICE BRAKES, HYDRAULIC | ||||||||||||||||
| 09V110000 | NAVISTAR, INC | from 07/24/2000 to 12/19/2007 | V (Vehicle) | 48876 | 09/16/2010 | ODI | WORKHORSE CUSTOM CHASSIS | 04/03/2009 | 04/03/2009 | |||||||
| Defect Summary | Navistar is recalling certain model year my 2001-2008 workhorse w20, w21 and w22 chassis and certain model year 2009 through 2011 monaco rv admiral, arista, monarch, and riptide recreational vehicles 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 driver would normally have warning of the brake drag if undetected by the driver. | |||||||||||||||
| Consequence Summary | 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 | Workhorse dealers will replace all four bosch brake caliper assemblies free of charge. the safety recall began on september 16, 2010. owners may contact workhorse at 1-877-246-7731. | |||||||||||||||
| Notes | Workhorse recall no. 50901-c and 51101-c.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 . | |||||||||||||||
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| SERVICE BRAKES, HYDRAULIC | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V110000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V186000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V198000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V206000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V193000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V217000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
| EA07016 | WORKHORSE CUSTOM CHASSIS | 11/16/2007 | 08/19/2009 | OVERHEATING DISC BRAKE CALIPER | 09V204000 | |
| The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. the overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| SERVICE BRAKES, ELECTRIC | |||
| 06/17/2009 | 12505 | 1 | |
| Workhorse motor home 2004 rear left brake caliper failure. *tr | |||
| 05/13/2009 | 24780 | 1 | |
| Brake calipers did not release resulting in having to tow the motorhome to a freightliner shop for repair. as a result there was damage to the calipers, rotors, brake pads, sensors, hoses and axle caps. *tr | |||
| SERVICE BRAKES, HYDRAULIC | |||
| 09/01/2007 | 3 | 05/18/2005 | |
| 2004 georgie boy cruise master class a motor home on a 2004 workhorse chassis. consumer writes in regards to problem with brakes *tgw the consumer stated the problem first began in september 2007, when the brakes began overheating and smoking. the consumer had the rv towed . workhorse paid part of the bill because the rv was still under warranty. in august 2009, the brakes failed and the rv would not stop. the rv was towed again, where the braking system was repaired. in september 2010, the consumer received a recall letter from workhorse regarding a problem with the brakes. the consumer took the rv to a repair facility to have it inspected. the rv failed inspection, due to the braking system overheating and smoking. the consumer contacted workhorse while at the repair facility and workhorse refused to absorb the cost of having the rv towed to an authorized service center. the consumer informed workhorse, the brakes were overheating and smoking and he would not be able to drive it. a representative from the repair shop informed workhorse it was their responsibility to have the rv towed. workhorse decided to pay for the towing. repairs were only made to the calipers. in july 2011, the rv would not stop and went out of control on the interstate, forcing the consumer off the highway. the consumer contacted workhorse again, to inform them of the brake failure and they refused to have the rv towed or pay for any of the repairs. *jb | |||
| 08/24/2010 | 1 | ||
| Consumer states that his 2004 damon intruder on a 2004 w22 workhorse custom chassis experienced the caliper defects resulting in safety recall 50901-c. consumer requests reimbursement for replacement calipers. *tgw the consumer stated the brakes overheated to the point that a severe wobble had developed in the front wheels and was causing the steering wheel to oscillate. the consumer stated the repairs cost $ 3,089.49 of which $1,751.10 was reimbursed by workhorse. the consumer is requesting the remaining of the repair bill. *jb | |||
| 11/10/2010 | 1 | ||
| 2004 southwind motorhome on a 2004 workhorse w22 chassis. consumer states that it is involved in the workhorse recall for defect with bosch brakes. he states that he had to get a complete brake job. consumer would like reimbursement for repairs. *kb all four rotors were cracked and had to be replaced. the consumer was denied reimbursement based on the brake problem being caused by fatigue. *jb | |||
| 01/03/2011 | 1 | ||
| 2004 dolphin motor home on a 2004 workhorse w22 chassis. consumer feels that because of the defective calipers he should not have to incur the repair expense, since he received a recall notice. *tgw the consumer stated it was discovered that all four calipers were defective, which caused the pistons to hold the brake pads out and rub, which generated heat. the heat caused all four rotors to crack, which in turn wore out the disc pads. *jb | |||
| 06/26/2010 | 1 | ||
| 2004 workhorse w22 chassis. consumer states the right rear brake rotor froze causing a burning smell. sent the coach in for repair and was charged for the repair. he feels that the failure was a cause from the recall. *kb the consumer stated a week after the rv was inspected, the abs light illuminated. the consumer was charged for the replacement of the abs sensor, rotors, pads and calipers. *jb | |||
| 01/03/2011 | 1 | 12/01/2009 | |
| 2004 winnebago adventurer on a workhorse w22 chassis. consumer states that his rv falls under the workhorse brake recall. *kb the consumer stated all four brake discs were cracked. *jb | |||
| 09/01/2010 | 1 | ||
| 2004 pace arrow on a 2004 workhorse w22 chassis. consumer states brake failure *tgw the consumer was informed by the repair shop that a recall had been issued regarding the brakes. the consumer stated he never received a recall letter in the mail. several weeks later, the consumer received the recall letter in the mail. the repair shop contacted the consumer to inform him the left front brake was not eligible for replacement under the recall. *jb | |||
| 04/01/2009 | 3 | ||
| 2004 fleetwood pace arrow with a 2004 workhorse w22 chassis. consumer states problem with brakes *tgw the consumer stated he has experienced three issues with the brakes; the first incident occurred in april 2009. when he applied the brake, the pedal went to the floor, but he was able to pump the brake pedal and was able to come to a stop. he discovered the brake reservoir was low. the second issue occurred in may 2010. while driving, the abs light illuminated and again the brake fluid was low. there was also a heavy odor of burning brakes. the rv was taken to a repair shop. the consumer was informed the front brakes and calipers were dragging and there was a recall regarding the issue. the repair shop replaced both front brake pads and calipers and only the left front wheel speed sensor. the consumer was advised that the right front wheel speed sensor was damaged, but workhorse would not cover it. the third incident, the abs light illuminated again and the brake fluid was low. the consumer took the rv to a repair shop. upon inspection, the mechanic found both rear speed sensors were shorted out and that workhorse would not cover the repair. *jb | |||
| 09/08/2008 | 2 | ||
| Consumer requests reimbursement for brake related failures to coach *tgw the brake fluid leaking from the right front wheel was found to be oil from the overheated hubs. the oil filled hubs plastic caps melted when the calipers froze and the brake drag overheated the rotors and melted the wheel speed sensors. the consumer stated the same symptoms have returned again. *jb | |||
| 04/01/2009 | 16000 | ||
| Tl-the contact owns a 2004 workhorse w22. the vehicle was included in the recall associated with nhtsa campaign id number 09v110000, service brakes, hydraulic. the manufacturer was notified and he was informed parts were not available. the parts have been unavailable for approximately sixteen months. the vehicle was not repaired. the failure mileage was 16,000 and the current mileage was 24,000. the vin was unavailable. sm | |||
| 04/01/2008 | 2 | ||
| 2004 holiday rambler motor home on a 2004 workhorse w22 chassis. consumer states brake failure *tgw the consumer stated he experienced total emergency brake failure with no prior warning in april of 2008 and again in april 2010. both failures were exactly as described in the safety recall. workhorse denied the consumers claim in april 2008 stating the failure was due to poor maintenance. the second failure resulted in the consumer having to have all of the calipers replaced. both of the failures were a result of overheating of the brake fluid caused by the caliper sticking in the applied position. *jb | |||
| 04/21/2010 | 26456 | 1 | |
| 2004 holiday rambler/vacationer class a motor home (2004 workhorse w22 chassis). consumer states problems with brakes *tgw the dealer found both front brake rotors had heat cracks and they replaced the left front rotor, seals and pads. *jb | |||
| 04/29/2008 | 8339 | ||
| Tl* the contact owns a 2004 national sea breeze lx rv. the vehicle was equipped with a workhorse chassis w22. the contact was driving approximately between 45-55 mph on a mountain roadway. there was a strong burning odor coming from the brakes. the vehicle was pulled over and inspected. the front passenger side wheel bearing oil cap melted which resulted to oil leakage. the vehicle was towed to an authorized dealer. the technician stated the failure was contributed to overheated brakes. the front passenger side spindle bearings and front wheel oil sight glass were replaced. the vehicle was taken to an authorized dealer for the second time with replacement of the front driver side brake calipers. there was a recall under nhtsa campaign id number 09v110000 (service brakes, hydraulic). however, the part was unavailable for the remedy service repair. the contact had been waiting for a period of seven months for the recall part with concern of the potential safety hazard. the authorized dealer advised the part would be availability october of 2010. the failure mileage was 8,339. | |||
| 01/01/1901 | 1 | ||
| 2004 workhorse rv. consumer requests reimbursement for repairs done to motor home. consumer states repairs were required due to damage caused by brake failure and overheating as described and covered in the two interim safety recall notices. *tgw the consumer stated the brakes would grab then smoke and the abs light illuminated. *jb | |||
| 04/03/2010 | 20251 | ||
| Brake drag, abs lite on, brake smell inside motor home,shimmy, brake fade, oil seals leaking front wheels, grease dripping from king pin fitting, unable to get above 40 mph. this occurs within 25 miles of travel. garage certified by workhorse to repair said it would not be covered in safety recall because it was not bad enough. | |||
| 05/01/2007 | 2 | ||
| 2004 workhorse w22 chassis. 2004 motorhome class a/pace arrow caliper stuck. *bf the consumer stated there was a burning smell coming from the left front wheel and the abs light was on. he took the vehicle to an rv dealer where it was discovered the caliper was stuck on the left front wheel. in early november 2007 he encountered a similar problem involving the rear wheels and again the same situation was found and fixed. the consumer attached invoices and believed the problems he experienced fell under the recall that was issued. *jb | |||
| 04/07/2008 | 2 | ||
| 2004 pace arrow, 35-g rv motor home with a w-22 workhorse chassis. consumer requests reimbursement for expenses incurred for repairs due to recall 09v110000. *tgw the consumer stated the brakes locked up, the abs light illuminated and there was a smell of a burning fluid. an inspection revealed a left rear frozen caliper, the abs sensor had melted, the pads were scored and glazed, the left front wheel speed sensor was damaged, the caliper slides, pins and bushings were all dry which caused a bind when braking. the left and right rear rotors were resurfaced, the rear calipers and pads were replaced, the seal, both axles, spindle seals, rear abs sensors and left front abs sensor were all replaced and the caliper slides and pins were lubed. a year and several months later, the brakes failed to engage, the abs light illuminated again, and the burning fluid odor had returned. the wheels were inspected and brake fluid had splattered over the right front wheel. the right front wheel was extremely hot and smoking. the abs light was no longer on. however, when the consumer arrived to the nearest dealer, the brakes failed again and the abs light was back on. an inspection revealed the front calipers were dragging. the front calipers, inner oil seals, wheel speed sensors and the right front outer cover were all replaced. *jb | |||
| 01/18/2009 | 1 | 02/27/2006 | |
| 2004 workhorse w22 chassis. the consumer received a recall notice from workhorse which stated the clip that retains the engines fuel rail pulse damper may fracture leading to a fuel leak. *dt the consumer was having difficulty contacting someone regarding the recall notice he received. the consumer also complained about loss of brakes on the rv. when the consumer attempted to apply the brake to stop, the pedal went to the floor. he immediately pulled the safety brake and pumped what little brake pedal he had. the next day, the consumer drove to the dealer where he was informed a recall had been issued regarding the problem he experienced. *jb | |||
| 05/22/2009 | 8505 | 1 | |
| Brake failure when driving through town stopping for a light. *tr | |||
| 07/14/2009 | 43500 | 1 | |
| Tl*the contact owns a 2004 fleetwood pace arrow rv. the vehicle was built on a 2004 workhorse chassis w22. while driving approximately 60 mph on normal road conditions a burning smell was coming from the brake system. the driver pulled over to the side of the road. the vehicle resumed operation with the anti-brake system (abs) warning light indicator illuminated on the instrument panel. the warning indicator remained illuminated until the engine was turned off. the vehicle was taken to an authorized dealer for inspection. the anti-lock brake sensor melted which was replaced. nhtsa campaign id number 09v110000, service brakes, hydraulic is related to the failure; however, the recall remedy part was unavailable. there were concerns of the safety risks involved and the uncertainty of the availability of the part. the failure mileage was 43,500. updated 02/02/10 *bf updated 02/02/10.*jb updated 02/19/10. *lj updated 02/19/10.*jb | |||
| 09/15/2009 | 23941 | 1 | |
| Workhorse safety recall 50901-c event. front driver wheel chattered due to caliper sticking in closed position onto rotor, resulting in overheating that caused fluid to overheated and leak out of wheel hub. caliper required to be replaced. the consequences that occurred was that the vehicle could not be driven because brakes would not work properly. solution is for workhorse to replace calipers with ones that do not stick. ones current on vehicle are the type that are subject to the failure mode described above. *tr | |||
| 11/02/2009 | 36000 | ||
| Tl* the contact owns a 2004 work horse w22 chassis model tipping allegro. during brake application at 35 mph the pedal went completely to the floor. he engaged the parking brake to stop the vehicle. a mechanic could not identify the cause of the failure. the manufacturer stated a letter was sent to the owners advising that the calipers could cause the breaks to over heat and fail. however he never received the letter. he took the rv to the dealer. the dealer stated they will need to duplicate the problem to be able make any necessary repairs. he added that if any parts were replaced it would be replaced with the same material and it will not be a permanent remedy. the current and the failure mileages were 36,000. | |||
| 10/12/2009 | 17559 | 1 | |
| Workhorse chassis w22 2004 mileage 17500 miles brakes overheated, pads melted to rotors abs sensor on right wheel melted. had to replace rotors, pads and sensor. workhorse refuse responsibility because caliper malfunction did not destroy caliper enough even though they are aware of problems. parts wee left with repair shop who has pictures. *tr | |||
| 07/27/2008 | 1 | ||
| Consumer wants to be reimbursed for the repair work done on their 2004 fleetwood bounder for safety recall 50901-c. *nj while driving, there was an odor of hot brakes. the consumer stopped at a weigh station and checked the brakes, but they didn't seem very hot. after about 6 or 7 miles, the odor became stronger. the consumer pulled over and when checking the brakes, the anti-lock sensor on the drivers side blew out. the next day, the rv was taken to a shop where it was discovered the calipers had froze and needed to be replaced.(workhorse 2004 w22 chassis) *jb | |||
| 08/13/2009 | 31254 | 1 | |
| Tl*the contact owns a 2004 tiffin allegro bay motor home with a w22 workhorse chassis. the contact stated that during application there is abnormal heat generation at the wheel end which causes brake drag and sticking. this can eventually lead to soft pedal conditions due to brake fluid boil, and possible extended stopping distance increasing the risk of a crash. he contacted the dealer in reference to recall# 09v110000 (service brakes, hydraulic), but because the parts were unavailable the failures have not been properly remedied.. the failure mileage was 31,254. the consumer stated he had to apply the brakes when a vehicle suddenly pulled in front of him. when he started to accelerate, he noticed the rv wasn't accelerating and he immediately pulled over. he discovered the rear wheels were extremely hot to touch and brake fluid was boiling out of the reservoir. the rv was inspected and it was discovered that the right rear caliper had frozen to the rotor. workhorse authorized the replacement of the brake shoes and caliper. updated 09/29/09.*jb updated 01/13/10. *jb | |||
| 07/25/2009 | 1 | ||
| 2004 workhorse had a problem with the brakes locking up. *nj the consumer took the rv to a repair shop and was informed two of the brake cylinders had locked up. workhorse denied the consumers claim stating the damage was normal wear. the mechanic, however stated there was a recall regarding this very issue. *jb | |||
| 07/31/2009 | 34060 | 1 | 12/01/2003 |
| Tl*the contact owns a 2004 four winds infinity 35f rv. the vehicle was equipped with workhorse custom chassis brakes. while driving approximately 10 mph, the brake pedal extended to the floor when it was depressed. the contact experienced extreme difficulty slowing down the vehicle. suddenly, the abs warning indicator illuminated on the instrument panel. the parking brake was engaged and the vehicle proceeded to a complete stop. the warning indicator remained illuminated until the engine was turned off. the vehicle resumed operation after being parked for two consecutive days. the vehicle was taken to an authorized dealer for inspection, but they could not determine the cause of the failure. in addition, the rotors were cracked. currently, the vehicle is being repaired at the cost of $2,500. the authorized dealer notified the manufacturer concerning the recall remedy repair; however, the manufacturer has refused to repair the vehicle because the caliper failure has not yet been confirmed. the failure and current mileages were 34,060. updated 09/01/09. *lj the seals and calipers were replaced. the left front wheel was dragging and overheated. updated 09/09/09*jb | |||
| 07/09/2009 | 31540 | 1 | 10/12/2004 |
| Tl*the contact owns a 2004 itasca sunova on a workhorse chassis. while driving 35 mph, the steering tightened up. when the contact pulled into the driveway, he noticed smoke coming from the rear passenger side caliper. he allowed the rv to cool down for a few days before driving it to the dealer. the dealer stated that the rear passenger side caliper was defective, which caused the brakes to drag and overheat. the manufacturer stated that they will provide the caliper and he will pay for the labor. the failure mileage was 31,540 and current mileage was 31,544. updated 8/28/09 *cn updated 09/04/09.*jb | |||
| 12/01/2008 | 3 | ||
| Safety recall 50901-c on 2005 allegro motor home. *nj the consumer has a 2004 workhorse w22. in december 2008 the consumer began to experience a brake dragging sound, so he took the motorhome to the dealer for an inspection. the shop determined that the brake linings were bad, even the motorhome had only 32,000 miles. the calipers contained a little rust, and they were cleaned and re-installed. on january 6, 2009 the consumer smelled a burning smell. examination of the tires revealed an overheated rear tire. the problem was with the caliper, which was replaced. on march 29, 2009 the motorhome began to pull to the right and there was a smell of smoke. the consumer pulled over and discovered the right front tire was smoking and red hot fluid was leaking from the wheel. the consumer went to a local shop and was told the problem was the calipers. *jb | |||
| 07/06/2009 | 20840 | 1 | |
| Brake failure on fleetwood 2004 pace arrow motor home. *tr the consumer is seeking reimbursement for the replacement of the rear calipers. 2004 workhorse w22. updated 10/07/09 | |||
| 07/03/2009 | 42000 | 1 | |
| After two hour trip in an 04 winnabago w22 chasis we discovered the brakes were dragging and subsequently boiled the brake fluid ; brake pedal to the floor! *tr | |||
| 08/22/2007 | 18000 | 2 | |
| Tl*the contact owns a 2004 four winds infinity with a class a workhorse chassis. the contact stated that the brake calipers locked on the front wheel. the rv was towed to the dealer and repaired at the contact's expense. she later received a recall notice from the manufacturer for the same repairs that were previously made on the brakes. the manufacturer stated that the engineers were still working on an effective remedy for the failures. the contact did not feel that this was acceptable. the nhtsa campaign id number was unknown. the failure and current mileages were less than 18,000. updated 08/04/09. *lj the consumer stated while driving, there was an odor present as though something was burning. the consumer pulled over and discovered a huge plume of smoke arising from the left front of the rv. the brake caliper had locked the pads against the rotor. the rv was towed and the next day, the consumer was informed the rotor on and brake pads were destroyed. the consumer experienced the same problem again 2 years later. updated 08/10/09.*jb | |||
| 09/01/2007 | 1 | ||
| Ltr re: safety recall 50901-c interim notice dated may 2009 workhorse he thinks he should be reimburse for the damages incurred in sept. 2007 from this defect, also pay for the diagnosis of this problem. *nj the consumer stated he experienced brake failure prior to receiving a recall letter. workhorse denied the consumers claim stating the repairs were necessary, because it was the consumers fault that the brakes overheated. the rotors were severely damaged. the consumer stated he had no confidence that the problem had been fixed even though the repairs were made, the abs light would still illuminate. the consumer stated he had spoken to a workhorse advisor twice prior to the brake failure. he reported the steering wheel was vibrating when he applied the brake. the consumers wife also smelled burnt brakes even though the consumer was only tapping the brakes to slow down. the advisor told the consumer it did not make sense that when stepping on the brake, the steering wheel would vibrate and that it was not a brake problem. a visual inspection revealed that the brake pads seemed ok, but the front rotors and one of the rear rotors were totally broken. the serpentine belt was replaced because it was making a lot of noise, the spark plugs burned 4 times, the pixels went out on the odometer, the instrument cluster shut down completely, the transmission locked up once in third gear, the seat belt light illuminated for no reason and then would go out and a rear seal on the axle leaked. *jb | |||
| 09/01/2008 | 1 | ||
| 2004 winn 35u - workhorse chassis - safety recall 20901c. consumer lost control of the front brakes on his motor home. *nj the consumer received a recall notice after the incident. the calipers and abs sensors had to be replaced and the rotors had to be turned. *jb | |||
| 07/17/2006 | 13125 | 3 | 02/10/2005 |
| Tl*the contact owns a 2004 workhorse w22 chassis. while driving approximately 25 mph on normal road conditions, the brake pedal extended to the floor without resistance when pressure was applied. the contact smelled a strong burning odor coming from the brakes. the vehicle coasted to a parking lot and roadside assistance was called to the scene. the vehicle was towed to an authorized dealer for inspection and they stated that the failure was related to the rear passenger brake calipers. the repairs were performed under warranty. the vehicle was taken back to the dealer on two separate occasions for identical failures. the repairs consisted of replacing the rear driver's and front passenger side brake calipers. the vin was included in nhtsa campaign id number 09v110000 (service brakes, hydraulic); however, the recall remedy has not been performed because the necessary part is on a national back order. the technician stated that the part will not be available until october of 2009. the failure mileage was 13,125 and the current mileage is 21,910. updated 6/29/09 *cn the right rear caliper seized and burned the rotor and pads. a year later, the consumer stated he experienced a problem again with the left rear caliper hanging. the caliper was replaced and fluid was added. the problem happened for a third time. updated 06/30/09.*jb | |||
| 05/14/2009 | 23000 | ||
| Tl*the contact owns a 2004 workhorse w22. while driving at an unknown speed, the abs light illuminated on the instrument panel. there was also an issue with the brakes, but the contact continued to her destination. she depressed the brake pedal again and the pedal extended to the floor, barely slowing down the vehicle. after reaching her destination, the contact noticed a burning smell coming from the brake area. she parked the vehicle and a family member drove it to a repair shop. the brakes functioned correctly after they cooled down. the vehicle is currently being repaired according to nhtsa campaign id number 09v110000. the contact was concerned that if only one side of the brakes was being repaired, the other side would fail in the future. she left voice messages with the manufacturer, but has not yet spoken to anyone. the current and failure mileages were approximately 23,000. | |||
| 08/21/2007 | 16205 | 1 | |
| I purchased an allegro motor home with a workhorse chassis on january 26, 2007 with 11, 619 miles. i carried the motorhome to menton's auto & truck center, inc for service and was advised the vehicle needed the brakes replaced due to excessive wear. the motorhome had 16, 205 miles at this time. i discussed this with several friends owning motorhomes and was advised this seemed excessive and the brakes should have lasted for a much grater time. this repair consisted of front and rear brake pads, seals, and turning rotors. *tr | |||
| 05/26/2009 | 27000 | 1 | 06/01/2004 |
| Tl*the contact owns a 2004 workhorse safari track coach model 706598 with a workhorse w22 chassis. the contact received a recall notice for nhtsa campaign id number 09v110000 (service brakes, hydraulic). the notice stated that the parts for the repair would be unavailable until late fall of 2009. the contact feels that the parts for the brake repair should be available at an earlier date. the current and failure mileages were 27,000. updated 06/12/09 *bf updated 06/16/09.*jb | |||
| 04/03/2009 | 17000 | 1 | |
| I have a 2004 national rv dolphin on a workhorse w22 chassis. i recently experienced this brake lock up issue as indicated safety recall 50901-c. vehicle has 17,000 miles prior to this one time occurrence. i was able to pull off the road and placed a roadside assistance call. the warning i obtained was the overheated brake smell and smoke from right rear wheel. when technician arrived and inspected, no issues could be found as rear wheels rotated freely. repeated brake tests indicated no failures. technician could still smell the brake odor and could tell rotor had overheated due to color. *tr | |||
| 03/09/2009 | 23800 | 1 | |
| I was driving along interstate 4 and stopped at a rest area after noticing diminished braking on my motorhome. i immediately detected the smell of overheated brakes. i then proceeded cautiously and pumped the brakes, noting that the abs system failure light was luminated on the dash. the problem with the brakes seemed to diminish, but noted that the efficiency of the brake system was significantly less than prior to the overheating. i have learned of the long history of the exact problem with the braking system on the workhorse custom chassis, and that a recall for this exact problem was ,ade, but stopped short of covering all of the affected vehicles, and that you are investigating this matter under odi number ea07016. the chassis was built in october, 2003. *tr | |||
| 01/18/2009 | 1 | 02/27/2006 | |
| 2004 gulf stream sun voyager (workhorse custom chassis w22) recall notice on campaign no. 60601-c for the clip that retains the engine fuel rail pulse damper may fracture leading to a fuel leak. *nj the consumer also stated a more serious problem was the loss of brakes while on a camping trip. when the consumer was approaching a red light, he attempted to apply the brakes, but the pedal went to the floorboard. he immediately pulled the safety brake and pumped what little brake pedal he had. the consumer managed to stop in time. the consumer took the rv to a repair shop and was informed a recall had been issued for the same problem, where the brakes overheat and fail. *jb | |||
| 02/02/2009 | 31400 | 1 | |
| Winnebago adventurer 2004, sold to original owner dec 6, 2003 - we are second owners - we purchased in feb 2005 w22 workhorse chassis, 22,000 lbs. motorhome is on 2003 or maybe 2002 workhorse chassis 31,569 miles on coach at time of repair 2/19/2009 incident occurred at approximate 31,400 miles on 2/2/2009. feb 2, 2009. drove motorhome from wachula to orlando campground. we smelled something like hot plastic when exiting mh. hubs were cool. there was not indication of a brake problem during the 70 mile trip from wachula to orlando. no drag on brakes, no loss of braking that would alert us to a problem. turned off engine to register. restarted and abs light would not go out when ignition was on. chassis is workhorse. called workhorse and were advised we could drive motorhome to seffner approx 60 miles away. appt. set for 2/16/2009. abs light remained on entire drive. when tech adv started up motorhome the abs light would not come on. at lazy days, diagnostics showed all sensors had failed, calipers and rotors showed signs of heat. we had brakes on all four wheels replaced. our extended warranty (national warranty of florida) paid for one of the four to be replaced, stating that according to their diagnostics only one sensor had failed. we are unable to fine any recall for the brakes on our year coach but have seen some service bulletins. there were several other coaches in line to be repaired with the same problem we had. *tr | |||
| 01/01/1901 | 1 | ||
| Facsimile from congressman mckeon on behalf of constituent who has safety concerns with brake failures on motorhomes built on workhorse chassis corp w-20 and w-22. *nj all 4 rotors on the consumers rv were cracked all the way through. the problem was discovered during routine maintenance. *jb | |||
| 11/17/2008 | 17000 | 1 | |
| Left rear brake caliper locked causing overheating and loss of all braking, resulting in emergency maneuvering of motor home out of traffic to parking lot without any brake assistance. workhorse warranty replaced all parts. next trip we had overheating of rt rear, workhorse authorized repairs again. approximately 700 miles later the coach was pulling hard to the right and the rt front caliper is stuck. workhorse refuses to take any responsibility for repairs let alone the safety of the situation. *tr | |||
| 11/05/2008 | 23500 | 1 | |
| The left rear rotor locked up causing the brakes to overheat and smoke from the wheel housing. this is the second such failure. the failure has not been fixed, the parts are on order. *tr | |||
| 10/11/2008 | 15300 | 1 | |
| Applied the brakes while traveling at 50 mph. several miles later, noticed a smell and saw smoke off of the rear brakes. abs light illuminated. pulled over to the side and found the rear brakes had locked. the rear calipers, brake pads, and abs sensors on both sides needed to be replaced (over $1,000). service shop indicated that the caliper pins were properly lubed. the rubber gaskets around the pistons had charred and tempering marks were noted on the calipers from the incident. *tr | |||
| 05/15/2008 | 1 | ||
| I own and operate a motor home sales facility. this year i have purchased four 04-05 model units of different makes on the workhorse chassis. on every unit i have had a problem with the abs system. on a trip home with one of the units i had the brake pedal go almost all the way to the floor but was able to stop. for the next few miles i drove very slow and kept checking my brakes. all at once the full pedal came back and never gave any other problem other than the abs light came on and required a new sensor. every unit has had at least one bad sensor. now i have an 04 in the shop with a warning light but no codes in the computer and an 06 with an abs light the comes and goes with no reason. someone needs to check this out. too may units with similar problems. *tr | |||
| 07/30/2008 | 14250 | 1 | |
| We currently own a 2004 allegro bay 34xb motor home on workhorse w22 chassis . at the time of the occurrence it had approximately 14250 miles on the chassis. after driving from myrtle beach about 35 miles on july 30, 2008 we stopped to refuel and smelled burning brake pads in the rear of the vehicle. when we started back out the abs warning light came on and stayed illuminated. since it was late in the day we decide to return home and try to get the vehicle checked the following morning. on the way home we experienced a reduction in brake performance when stopping. on july 31, 2008 we brought the vehicle to larry | |||
| 08/12/2008 | 32700 | 1 | |
| Operating a 2004 fleetwood pace arrow 35g motorhome on a workhorse chassis w22, flat towing a 2002 honda civic. traveling rt 41 in pa. from new jersey. i was operating in mild to light traffic on a hilly road between avondale and gap, pa. at first i smelled what i think was and electrical scent. soon after i loss brake pedal pressure. pumping the pedal improved brake usage. personally examined the master and all four brakes under the motorhome for fluid loss. none observed next day drove short distance to a quality auto / truck repair in gap, pa. and informed them of the incident and requested they survey the brake system for problems. they found none. drove back home to egg harbor twp., nj without a problem. *tr | |||
| 08/04/2008 | 23400 | 1 | |
| Took motorhome (workhorse w22 chassis) to get gas, approx 5 miles. got gas and returned. little traffic, flat road, 45 mph. upon return, both front brake rotors were smoking. this follows previous failures of both rear brakes. motorhome has less than 24,000 miles and has been well maintained, including two complete replacements of brake fluid. notified workhorse and they responded that the vehicle is out of warranty and not involved in any brake recalls. this report is a duplicate of 10237294 which was filed under the motorhome name instead of the workhorse chassis. *tr | |||
| 08/07/2008 | 24050 | 1 | |
| On sep. 12 of 2007, we left on a trip from our home to las vegas, nv. on the first leg of our trip our we noticed we were getting very poor gas mileage and it seemed like our brakes were dragging. we pulled over at the welcome center in louisiana on i-59. we noticed the rear brakes smelled hot. when we went back into the motorhome and started it back up the abs warning light was on. we then called a workhorse service center, ross downing chevrolet. the mechanic told us to wait for an hour and drive it to hammond to the dealership and he would work on it. the mechanic replaced the rear rotors, calipers, pads and wheel sensors, then reset the abs warning light. all was good until we went over the hoover dam and the abs light came back on and we pulled over and let the brakes cool down again and then drove to our campground at nellis air force base in las vegas. then once we were there we called and made an appointment with findlay rv. they replaced the wheel sensor on the front left wheel. and reset the codes. the date of the front wheel incident was approx. sep 21 2007. now for the most recent incident. august 7, 2008, we were traveling to biloxi, ms from our home and i noticed our gas mileage decreasing again. we pulled over and smelled that the left front wheel area was hot. we let the brakes cool again and from our previous experience and because we are so close to home we decided to just go ahead and stay in biloxi because i had an appointment at the va center in biloxi the next day. we are going to take the motorhome to a service center to have the abs warning light checked out and repaired. i believe that 3 times in a year is a bit excessive to have problems with the abs system and needs to be investigated especially since our motorhome is only 4 years old. also, my parents own a 2003 workhorse w22 chassis also and have had problems with their abs warning light also. *tr | |||
| 07/27/2008 | 12000 | 1 | |
| Overheating brake problems on workhorse w22 motorhome chassis (2004) 3rd time this has occured. twice on different wheels. *tr | |||
| 06/22/2008 | 23000 | 1 | |
| The left rear brakes locked-up causing smoke to and the strong odor of brake material. i removed the caliper and pushed the pistons bake into the caliper. this is the first incident with the brakes in 23,000 miles, but has been an issue with the workhorse w-22 chassis. *tr | |||
| 04/07/2008 | 12000 | 1 | |
| My workhorse brakes went out, i only had 12,000 miles at the time on my new motorhome. *tr | |||
| 04/26/2008 | 16450 | 1 | |
| I had a problem and complaint with the brakes on our winnebago motorhome just as described in your nhtsa action ea07016. it was difficult to duplicate just as your investigation has found. this first happened in november 2007 and again in april 2008. i found an independent motorhome repair shop that had seen this complaint with 2 prior units and had repaired them. ken meads with motorhome service in hot springs, arkansas seems very versed in this problem. his number is 501-609-0145. i am not happy with workhorse or bosch as they seem to think this in not their problem. i am looking forward to some type of resolution to this problem and re-imbursement of my expenses for repair. *tr | |||
| 10/17/2007 | 13574 | 1 | |
| Front right brake caliper locked up heating rotor and damaging pads, rotor, and abs sensor. *tr | |||
| 05/02/2008 | 6500 | 1 | |
| 2004 workhorse w22 motorhome chassis. right rear brake shoes not releasing from rotor causing brakes to over heat. damage unknown. rv scheduled for inspection may 6, 2008. 6500 miles. driven only occasionally. *tr | |||
| 02/22/2008 | 1 | 12/19/2003 | |
| Brakes locked up on my 2004 workhorse w22 chassis. i had to replace all 4 caliper, brake pads and all 4 abs wheel sensors. *tr | |||
| SERVICE BRAKES, HYDRAULIC - ANTILOCK | |||
| 12/14/2007 | 21343 | 2 | 02/02/1973 |
| 2004 workhorse w-22 chassis front brake failure. workhorse will not admit they have a problem, and will not assist me in fixing them. 22k miles on chassis and they say i must pay for repairs. they should be sued for such poor business ethics. local dealer admits to repairing this type problem a minimum of 5 times a month! will cost me 2-3000 dollars out of my pocket. poor design, with numerous accounts of failures, they should have to pay for repairs! *tr | |||
| SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS | |||
| 12/01/2008 | 26000 | 1 | 12/17/2003 |
| Tl*the contact owns a 2004 winnebago adventurer workhorse chassis. the contact stated that the calipers seized and burnd through the brakes while driving long distances. the failure was noticed while driving 50 mph. he felt that the rv was unsafe to drive because the brakes were constantly malfunctioning while driving. the current mileage was 31,080 and failure mileage was 26,000. updated 02-23-09 *bf updated 02/24/09. *jb | |||
| SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - DISC - CALIPER | |||
| 07/31/2009 | 34060 | 1 | 12/01/2003 |
| Tl*the contact owns a 2004 four winds infinity 35f rv. the vehicle was equipped with workhorse custom chassis brakes. while driving approximately 10 mph, the brake pedal extended to the floor when it was depressed. the contact experienced extreme difficulty slowing down the vehicle. suddenly, the abs warning indicator illuminated on the instrument panel. the parking brake was engaged and the vehicle proceeded to a complete stop. the warning indicator remained illuminated until the engine was turned off. the vehicle resumed operation after being parked for two consecutive days. the vehicle was taken to an authorized dealer for inspection, but they could not determine the cause of the failure. in addition, the rotors were cracked. currently, the vehicle is being repaired at the cost of $2,500. the authorized dealer notified the manufacturer concerning the recall remedy repair; however, the manufacturer has refused to repair the vehicle because the caliper failure has not yet been confirmed. the failure and current mileages were 34,060. updated 09/01/09. *lj the seals and calipers were replaced. the left front wheel was dragging and overheated. updated 09/09/09*jb | |||
| 07/01/2008 | 12800 | ||
| Tl*the contact owns a 2004 gulf stream sun voyager rv. the vehicle has a workhorse w22 chassis. in july of 2008, the front driver's side caliper caught fire. the caliper was replaced. on may 22, 2009, the contact felt the vehicle pulling to one side while driving 65 mph. she pulled the vehicle over and noticed that the rear passenger side caliper was overheating. the vehicle was taken to the dealer and they replaced the caliper. the manufacturer filed a report and requested documentation in order to consider providing reimbursement. the failure mileage was 12,800 and current mileage was 13,889. | |||
| 02/17/2008 | 20000 | 2 | 06/16/2004 |
| Right rear brake caliper over heating. *tr | |||
| 02/07/2008 | 22125 | 1 | 07/28/2006 |
| Brake failure on 2004 workhorse 22 chassis with less than 22,000 miles. left rear caliper locked up, master cylinder fluid boiled over, abs sensor melted. both rear calipers replaced, all hoses, abs sensors, pads, wheel bearings. no accident, injuries or fire. this chassis is on a 2004 pace arrow motor home. we were able to get into an rv park within a mile by pumping brakes. all parts are available, with the exception of calipers which were exchanged for core charge. *tr | |||
| 01/07/2008 | 26700 | 2 | 05/25/2004 |
| Rear brake calibers failing and replacing at 16,000 miles and the front doing the same at 26,500 miles...information below is for the recent failure, the rear failed in 2007. *tr | |||
| 08/20/2007 | 12000 | 1 | 04/13/2005 |
| Complete brake failure at 55 mph due to rear brake being locked up and overheating. mechanic said it was defective calipers. *jb | |||
| 03/09/2006 | 16045 | 1 | 03/09/2004 |
| On 9 mar 2006 i was traveling on la highway 128 enroute to winnsboro, la in my 24' 2004 winnebago motorhome built on a workhorse chassis. time of day was around 7:30 am, road was dry and flat. temperature was probably in high 60's (deg f) to low 70's. i had engaged cruise control at 50 mph and overdrive was engaged. without warning the steering column began to violently shake, the allison 1000 transmission slipped out of od into 3d gear and then immediately shifted into 2d gear. cruise control remained engaged. engine speed remained at about 1500-1800 rpm but road speed dropped to nearly 0 mph. after shutting the engine down i smelled an odor of hot metal. i inspected the coach inside and outside but did not find any visible smoke or flame. i returned to the coach, restarted the engine, and proceeded without further difficulty. during the above described action the coach did not pull either right or left, and there were no alarms, either visual or aurally from the display lanel. this leads me to believe that the front left and right disk brakes closed on the rotors equally, causing the coach to come to a straight-line stop. i have read of previous models (2002 and perhaps 2003) of this same chassis equipped with bosch calipers having brake problems resulting in fires and other serious damage to the vehicle. i now believe that this problem is surfacing once again, this time in the 2004 workhorse chassis. a call to the manufacturer resulted in no offer of a possible cause, or other advice.*jb | |||
| SERVICE BRAKES, HYDRAULIC - FOUNDATION COMPONENTS - HOSES, LINES/PIPING, AND FITTINGS | |||
| 04/10/2011 | 1 | ||
| 2005 damon challenger rv on a 2004 w22 workhorse chassis. consumer states the hydraulic brake line is in contact with the exhaust system on both sides of the unit (rear axle) *tgw | |||