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 | 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 | 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 | 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 | 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. | ||||||
| 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 | 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. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| SERVICE BRAKES | |||
| 07/11/2012 | 25000 | ||
| Tl* the contact owns a 2005 workhorse w22 rv. the contact stated that while driving 55 mph, he smelled burning from the rear of the vehicle. the vehicle was taken to a mechanic who stated that they needed to replace the brake caliper assemblies. the vehicle was repaired. the manufacturer was contacted and stated that the vin was not included in nhtsa campaign id number: 09v110000 (service brakes). the failure and the current mileage was 25,000. | |||
| 07/11/2012 | 25000 | ||
| Tl- the contact owns a 2005 workhorse w22 rv. the contact stated that while driving 55 mph, he smelled burning from the rear of the vehicle. the vehicle was taken to a mechanic who stated that they needed to replace the brake caliper assemblies. the vehicle was repaired. the manufacturer was contacted and stated that the vin was not included in nhtsa campaign id number: 09v110000 (service brakes). the failure and the current mileage was 25,000. kmj | |||
| 07/11/2012 | 25000 | ||
| Tl- the contact owns a 2005 workhorse w22. the contact stated while driving 55 mph when he smelled like the back of the vehicle was burning. the vehicle was taken to a mechanic. they stated that they needed to replace the brake caliper assemblies. the vehicle was repaired. the manufacturer was contacted and they stated that the vin was not included on recall (nhtsa campaign id number: 09v110000,component: service brakes). the failure and the current mileage was 25,000.jp | |||
| SERVICE BRAKES, HYDRAULIC | |||
| 03/01/2012 | 1 | ||
| 2005 workhorse w22 motorhome. consumer writes in regards to recall concerning sticking brake calipers *tgw while replacing the calipers, the mechanic discovered that three of the brake rotors were cracked. the consumer felt it was a premature failure of the brake rotors and constituted a safety hazard. | |||
| 10/21/2011 | 31300 | ||
| I had new tires put on this motorhome and the mechanic showed me front rotors were both cracked and reminded me of the bosch caliper recall. i checked my vin # on workhorse web site and it showed the recall for my chassis. i took it to bob stall chevrolet in san diego to handle the recall. i was informed workhorse denied the rotors were damaged by the possibility of the calipers not releasing and overheating and cracking the rotors. i have never even smelt hot brakes on this motorhome since i have owned it. i was surprised to see cracked rotors especially this size of rotors. i have done all my own vehichle maintenance for the last 35 years including many brake jobs. i have rarely even had to turn rotors on any of my autos,b usually just change pads or shoes. i am extremely conscious of how i use my brakes especially on the motorhome as this is my third one in 20 years. i had a bounder on a ford chassis for ten years prior to this workhorse and i changed the pads at 40k miles with no issues with rotors or calipers. my problem is that i am paying $1600.00 to have new rotors and pads with seals on a 5 year old chassis. this is totally unaceptable especially for something i paid $130,000.00 for. i beleive these rotors were either damaged by sticking calipers or uneven tempering during the manufacturing process of these rotors. | |||
| 05/15/2010 | 14751 | ||
| Tl-the contact owns a 2005 national sea breeze lx motor home with a workhorse w22 chassis. while driving 65 mph he engaged the brake and they began to shake. he stated the front wheels were shaking. the contact stated he received recall notice nhtsa campaign id number: 09v110000, service brakes, hydraulic and the recall work was performed on the vehicle in 2010. after the recall worked was performed while driving the brakes got hot. the contact stated he was traveling and called the dealer and was advised to take his vehicle to a dealer in the area. the vehicle was taken to an authorized dealer and he was advised the front rotors were warped. the vehicle was repaired in october 2010. the contact stated he was having problems with the rear brakes now. the contact called the manufacturer and the representative advised him it was user error. the vehicle was not repaired. the failure mileage was 14,751 and the current mileage was 15,700. vwb | |||
| 09/01/2009 | 2 | ||
| 2005 workhorse w22 chassis. winnebago adventurer. consumer states brake failure *tgw the consumer stated in september 2009 while driving, the brakes failed for the first time. the consumer and his wife began to smell the brakes burning. the abs light illuminated, the front wheels were too hot to touch and the rear wheels were hot as well. the rv was taken to a local workhorse facility. they replaced a cracked caliper, but did nothing to the brakes. in august 2010, the brakes failed again. the rv was towed to a workhorse facility. they replaced the front calipers, front center caps and three abs sensors. a claim was submitted to workhorse, but the it was denied. workhorse stated the brake failure was not recall related. *jb | |||
| 09/27/2010 | 1 | ||
| Consumer writes regarding 2005 workhorse chassis recall *tgw the consumer stated when he took the rv in for service, he advised the technician that there was an odor and smoke coming from the brake system during light and heavy braking. after inspection, the technician determined the brake calipers were in fact defective. they also determined that the rotors were heat damaged to the point that the rv was unsafe to drive. also, the brake pads were heat damaged and prematurely worn out. the consumer stated he would like workhorse to fulfill their obligations regarding the recall on the bosch brake calipers and the resulting damage to the brake system. *jb | |||
| 09/28/2010 | |||
| Tl- the contact owns a 2005 monaco simba rv equipped with a workhorse chassis w22. there was a recall associated with nhtsa campaign id number 09v110000 (service brakes, hydraulic); however, the part was on a massive back order. the contact stated that he was one hundred and forty forth on the waiting list and was concerned with the potential safety hazard. there was no failure mileage. js | |||
| 11/25/2007 | 29000 | ||
| Tl-the contact owns a 2005 monaco monarch rv equipped with a workhorse chassis w22. the vehicle was taken to an authorized dealer for a recall repair associated with the nhtsa campaign id number 09v110000 (service brakes, hydraulic). the contact stated the recall mentioned that the dealer would replace the rotors in conjunction to the four brake calipers replacement. the dealer refused to replace the overheated rotors under the recall remedy. the rear driver side rotor was replaced at the owner's expense. the three other damaged rotors were not replaced. in addition, the complete brake system had been previously replaced in october of 2007. the failure mileage was approximately 29,000. the vin was unavailable. js | |||
| 08/09/2010 | 11990 | 1 | |
| Letter from congressman davis on behalf of constituent requesting a recall on his 2006 fleetwood that he purchased from rv service & accessories of tennessee (dot/i 2010-2160-respond to rockwood, tn office) *tgw the consumer experienced complete brake failure at 11,990 miles. the consumer stated other chassis models were recalled, but not his model. *jb | |||
| 08/18/2007 | 7126 | ||
| Tl-the contact owns a 2005 holiday rambler admiral se motor home with a workhorse w22 chassis. while driving 40-45 mph he engaged the brakes and the brake pedal went to the floor. he stated he pumped the brakes and the vehicle slowed down. he stated he smelled something burning inside the vehicle. he later determine that it was the rear brakes that he had smelled. the vehicle was taken to an authorized dealer and the dealer replaced the rear brake calibers. the dealer also informed him that the failure was caused by the brakes freezing up. the contact does not feel safe driving the vehicle. he reference recall 09v110000, service brakes, hydraulic he stated the manufacture would not reimburse him because his vehicle was repaired in august 18,2007 and they did not take responsibility for the repairs until november 16,th 2007. the failure mileage was 7,126 and the approximately current mileage was 10,000. vwb | |||
| 08/09/2010 | 11990 | 1 | |
| Letter from congressman davis on behalf of constituent requesting a recall on his 2006 fleetwood that he purchased from rv service & accessories of tennessee (dot/i 2010-2160-respond to rockwood, tn office) *tgw the consumer experienced complete brake failure at 11,990 miles. the consumer stated other chassis models were recalled, but not his model. *jb | |||
| 08/18/2007 | 7126 | ||
| Tl-the contact owns a 2005 holiday rambler admiral se motor home with a workhorse w22 chassis. while driving 40-45 mph he engaged the brakes and the brake pedal went to the floor. he stated he pumped the brakes and the vehicle slowed down. he stated he smelled something burning inside the vehicle. he later determine that it was the rear brakes that he had smelled. the vehicle was taken to an authorized dealer and the dealer replaced the rear brake calibers. the dealer also informed him that the failure was caused by the brakes freezing up. the contact does not feel safe driving the vehicle. he reference recall 09v110000, service brakes, hydraulic he stated the manufacture would not reimburse him because his vehicle was repaired in august 18,2007 and they did not take responsibility for the repairs until november 16,th 2007. the failure mileage was 7,126 and the approximately current mileage was 10,000. vwb | |||
| 04/04/2010 | 9273 | ||
| Tl- the contact owns a 2003 workhorse w-22. he stated he got his first recall notice nhtsa campaign id number: 09v110000, dervice brakes hydraulic over a year and 1/2 ago. he has received three recall notices/updates so far and the parts still are not available. the owner is unable to use his vehicle because of safety concerns. the failure mileage and current mileages were approximately 9,272. rd | |||
| 06/27/2010 | 12400 | ||
| Tl-the contact owns a 2005 damon coaches challenger 353 rv equipped with a workhorse chassis w22. while the contact was driving approximately 35 mph, the brakes were applied followed by a sudden crunching noise and the vehicle began to pull into the right direction without assistance. the vehicle was able to continue traveling after slight force was engaged to the steering wheel. also, the vehicle would pull into the left direction unexpectedly. the failures were intermittent. there was a recall under nhtsa campaign id number 09v110000 (service brakes, hydraulic); however, the manufacturer remedy was unavailable. the recall notification was received in may of 2009. the contact was displeased to know that the recall part remained unavailable and expressed significant concern of the potential safety hazard. the vehicle had not been repaired at the time of the complaint. the failure mileage was approximately 12,400. js | |||
| 04/04/2010 | 9273 | ||
| Tl- the contact owns a 2003 workhorse w-22. he stated he got his first recall notice nhtsa campaign id number: 09v110000, dervice brakes hydraulic over a year and 1/2 ago. he has received three recall notices/updates so far and the parts still are not available. the owner is unable to use his vehicle because of safety concerns. the failure mileage and current mileages were approximately 9,272. rd | |||
| 06/27/2010 | 12400 | ||
| Tl-the contact owns a 2005 damon coaches challenger 353 rv equipped with a workhorse chassis w22. while the contact was driving approximately 35 mph, the brakes were applied followed by a sudden crunching noise and the vehicle began to pull into the right direction without assistance. the vehicle was able to continue traveling after slight force was engaged to the steering wheel. also, the vehicle would pull into the left direction unexpectedly. the failures were intermittent. there was a recall under nhtsa campaign id number 09v110000 (service brakes, hydraulic); however, the manufacturer remedy was unavailable. the recall notification was received in may of 2009. the contact was displeased to know that the recall part remained unavailable and expressed significant concern of the potential safety hazard. the vehicle had not been repaired at the time of the complaint. the failure mileage was approximately 12,400. js | |||
| 04/04/2010 | 9273 | ||
| Tl- the contact owns a 2003 workhorse w-22. he stated he got his first recall notice nhtsa campaign id number: 09v110000, dervice brakes hydraulic over a year and 1/2 ago. he has received three recall notices/updates so far and the parts still are not available. the owner is unable to use his vehicle because of safety concerns. the failure mileage and current mileages were approximately 9,272. rd | |||
| 06/27/2010 | 12400 | ||
| Tl-the contact owns a 2005 damon coaches challenger 353 rv equipped with a workhorse chassis w22. while the contact was driving approximately 35 mph, the brakes were applied followed by a sudden crunching noise and the vehicle began to pull into the right direction without assistance. the vehicle was able to continue traveling after slight force was engaged to the steering wheel. also, the vehicle would pull into the left direction unexpectedly. the failures were intermittent. there was a recall under nhtsa campaign id number 09v110000 (service brakes, hydraulic); however, the manufacturer remedy was unavailable. the recall notification was received in may of 2009. the contact was displeased to know that the recall part remained unavailable and expressed significant concern of the potential safety hazard. the vehicle had not been repaired at the time of the complaint. the failure mileage was approximately 12,400. js | |||
| 04/04/2010 | 9273 | ||
| Tl- the contact owns a 2003 workhorse w-22. he stated he got his first recall notice nhtsa campaign id number: 09v110000, dervice brakes hydraulic over a year and 1/2 ago. he has received three recall notices/updates so far and the parts still are not available. the owner is unable to use his vehicle because of safety concerns. the failure mileage and current mileages were approximately 9,272. rd | |||
| 06/27/2010 | 12400 | ||
| Tl-the contact owns a 2005 damon coaches challenger 353 rv equipped with a workhorse chassis w22. while the contact was driving approximately 35 mph, the brakes were applied followed by a sudden crunching noise and the vehicle began to pull into the right direction without assistance. the vehicle was able to continue traveling after slight force was engaged to the steering wheel. also, the vehicle would pull into the left direction unexpectedly. the failures were intermittent. there was a recall under nhtsa campaign id number 09v110000 (service brakes, hydraulic); however, the manufacturer remedy was unavailable. the recall notification was received in may of 2009. the contact was displeased to know that the recall part remained unavailable and expressed significant concern of the potential safety hazard. the vehicle had not been repaired at the time of the complaint. the failure mileage was approximately 12,400. js | |||
| 05/30/2009 | 21591 | ||
| Tl* the contact owns a 2005 workhorse w22 rv. the contact stated that he received an interim recall notice from workhorse to address the brake failure issue over a year ago (nhtsa campaign id number: 09v110000: service brakes, hydraulic). after receiving the recall notification while driving approximately 40 mph, he noticed an unusual burning smell and smoke coming from the front passenger | |||
| 05/30/2009 | 21591 | ||
| Tl- the contact owns a 2005 workhorse w22. the contact stated that he received an interim recall notice from workhorse to address the brake issues over a year ago. after that, while driving approximately 40mph he noticed a burning smell. he pulled over and discovered the right front wheel was on fire and smoke was coming from the left front. workhorse was notified and they sent a tow truck to tow the vehicle for repairs and they would reimburse him for the expense. the parts for nhtsa campaign id number: 09v110000 are not available at this time because nhtsa has not informed bosch of the recall procedures. the failure mileage was approximately 21,591. the current mileage is 24,791. rd | |||
| 10/12/2009 | 18510 | 1 | |
| I have a 2005 motorhome on a workhorse chassis which is involved with the bosch zops & zoht brake recall. our motorhome has 18,500 miles on it. on 10 sep 2009 we had the left front brake stick & overheat about 6-8 miles from home. after calling workhorse for assistance i decided to have the brakes checked. both front calipers were sticking. the left front rotor had heat damage & brake pad transfer on the rotor. the right front rotor had many small heat cracks with one large radial crack across & through the entire braking surface and also had brake pad transfer on the rotor. photos were taken of the damaged calipers, rotors & brake pads and emailed to workhorse for approval of replacement of these damaged items. workhorse covered the two bosch brake calipers but refused to cover any additional items saying they were damaged during normal operation. the service manager, service advisor and service tech at the workhorse facility i took the motorhome to, all said the sticking calipers caused the damage to the rotors & pads. i contacted the same workhorse tech (who denied our claim) twice to explain that i have a supplemental brake for the vehicle we tow, that i don't ride the brake and i don't brake hard to stop. i even asked him what he thought i might be doing that could possibly cause the damage to the rotor & pads. he would not respond. i have spent (out of pocket in the last week) $978.78 to have the motorhome front brakes put back into proper working order. i bought a new rotor for the right front, i had the lf rotor turned, bought seals, replaced brake pads both sides & replaced the brake fluid. i have photos of the damaged parts & the cracked rotor. without some intervention i doubt that i will ever be compensated for the cost i have incurred. i've been driving for 50 yrs. and i have never experienced any brake problems on any vehicle i have owned. *tr updated 11/04/09 | |||
| 06/05/2009 | 13128 | 1 | 01/15/2009 |
| 2005 winnebago has a workhorse chassis - workhorse has a problem with the brakes. *nj the consumer stated when he entered the camp grounds, he smelled rubber burning. upon checking the brakes, he discovered they had overheated. the consumer took the rv to a repair shop and was informed that workhorse had a problem with the brake slides rusting up and seizing the brakes. further examination revealed the front brakes and one rear brake were dragging. *jb | |||
| 05/20/2009 | 1 | ||
| Recall notice for brakes on workhorse rv motor home. *nj the consumer stated he experienced the problems as described in the recall letter and had the repairs made 2 days prior at a cost of $2,719.94. the calipers, abs sensor and hubs were replaced. *jb | |||
| 10/23/2007 | 11200 | 1 | |
| Left brake caliper lockup. happened once and overheated brake system until brake pedal went to floor. stopped and let cool then continued to a dealership where i was informed of the brake caliper lockup issue with workhorse chassis. continued trip and had brake job performed at dealership. one brake caliper was completely locked up. replaced both rear calipers, hoses, seals and other parts and old parts may still be available at the dealership. complete statement of work is available from lazy days rv center in seffner fl. *tr | |||
| 10/10/2007 | 25000 | 1 | 10/28/2005 |
| My brake does not return to the rest position after use at the speed it once did. it takes 1 to 3 seconds. *tr | |||
| 09/15/2007 | 2700 | 2 | 06/16/2007 |
| Took a trip in my 2006 motorhome on a 2005 workhorse w-22 chassis. while in stop and go traffic on the interstate the brake pedal seemed to climb higher the more times it was depressed.. after several miles of this i could smell burnt brake pad. upon getting out of traffic the problem went away and the pedal returned to normal height. 1 week later the same thing occurred on the return trip, also i could feel the brakes dragging. the unit had 2,700 miles on it at the time. placed unit in workhorse chassis dealer for repair on 10/23/07. they replaced 3 rotor assemblies, 3 calipers, 2 brake pad kits, and numerous seals and bearings which had been damaged by excessive heat.. actual cause has not been determined. *tr | |||