2001 Workhorse W22

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.

THIS INVESTIGATION WAS DERIVED FROM INFORMATION GATHERED DURING PE02-046, BOSCH DISC BRAKE CALIPERS.THIS INVESTIGATION FOCUSED ON THE VEHICLE MANUFACTURER, NEWMAR.SUBJECT VEHICLES WERE THOSE BUILT WITH A HYDRAULIC BRAKE SYSTEM INCORPORATING THE BOSCH ZERO OFFSET PIN SLIDE (ZOPS) CALIPERS.ODI'SCONCERN WASEXCESSIVE WHEEL END HEAT, POSSIBLY RESULTING IN A WHEEL END FIRE.DURING THE INVESTIGATION, ODI DISCOVERED TWO SPECIFIC NEWMAR VEHICLE MODELS, THOSE BUILT ON NEWMAR CHASSIS AND THOSE BUILT ON A WORKHORSE CHASSIS. AS A RESULT OF THE AGENY'S INVESTIGATION INTO THIS MATTER, ALL NEWMAROWNERS WILL BE NOTIFIED (04V-019) AND THE REMEDY WILL BE APPLIED TO THEIR VEHICLES. SOME NEWMAR VEHICLES (1,795) BUILT ON THE WORKHORSE CHASSIS ARE BEING RECALLED BY WORKHORSE (04V-084).THIS INVESTIGATION IS CLOSED.FURTHER DETAILS ARE PROVIDED ON PAGES 2, 3, AND 4.COPIES OF BOTH SAFETY RECALLS ARE ATTACHED.

TL* THE CONTACT OWNS A 2001 MONACO MONARCH EQUIPPED WITH A WORKHORSE W22 CHASSIS. THE CONTACT WAS DRIVING APPROXIMATELY 58 MPH AND APPLIED THE BRAKES, WHICH BEGAN TO PULSATE ABNORMALLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE FRONT BRAKE PADS, CALIPERS AND BOTH FRONT ROTORS WERE REPLACED. THE REPAIRS WERE MADE THREE SEPARATE TIMES. THE FAILURE PERSISTED AFTER EACH REPAIR WAS PERFORMED. THE CONTACT PLANNED TO REPLACE THE PASSENGER'S SIDE ROTOR HIMSELF. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 5,000.

NHTSA ID

10526214

Incident

Feb 1, 2002

Mileage

5,000 mi

TL*THE CONTACT OWNS A 2001 WORKHORSE W22 CHASSIS. THE CONTACT STATED THAT THE BRAKES MALFUNCTIONED AND LOCKED WHILE HE WAS DRIVING WHICH CAUSED THE ABS SENSOR TO MELT. THE BRAKES WERE REPLACED TWICE BUT THE FAILURE CONTINUED TO OCCUR. THE CONTACT REFERENCED RECALL 09V110000 AND STATED THAT WHEN HE CALLED THE MANUFACTURER, HE WAS TOLD THAT REPAIRS WERE NOT SCHEDULED TO BE PERFORMED UNTIL OCTOBER 2010. HE WAS ALSO TOLD THAT IF THE PROBLEM OCCURRED AGAIN, HE SHOULD CONTINUE PUMPING THE BRAKE PEDAL TO ACTIVATE THE BRAKING SYSTEM. THE CONTACT FELT THAT IT WAS A SAFETY CONCERN WHICH COULD CAUSE A FIRE OR CRASH TO OCCUR. THE CURRENT MILEAGE WAS APPROXIMATELY 31,000. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10348199

Incident

Apr 20, 2005

TL* THE CONTACT OWNS A 2002 FLEETWOOD SOUTH WIND RV WITH 2001 WORKHORSE W22 CHASSIS. WHILE DRIVING AT 15 MPH, THE CONTACT NOTICED AN UNUSUAL BURNING ODOR AND THE BRAKES WERE NOT OPERATING AS NORMAL. THE CONTACT DISCOVERED THE BRAKE FLUID WAS EXTREMELY LOW AND WAS CAUSING THE BRAKE FAILURE. THE MANUFACTURER VERIFIED THE VEHICLE WAS INVOLVED IN NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC) AND THAT THE VEHICLE WOULD NEED TO BE INSPECTED BEFORE RECALL REPAIRS WERE PERFORMED. THE CONTACT WAS NOT COMFORTABLE WITH DRIVING THE VEHICLE TO THE DEALER FOR FEAR OF A POSSIBLE FAILURE OR CRASH. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 40, 200. UPDATED 07/29/10 *BF THE CONSUMER EXPERIENCED BRAKE FAILURE DUE TO FAULTY PISTON IN THE BOSCH CALIPERS. THE ABS LIGHT DID NOT ILLUMINATE TO INDICATED THERE WAS A BURNT SENSOR. UPDATED 08/03/10*JB

NHTSA ID

10336756

Incident

Jun 2, 2010

Mileage

40,200 mi

LETTER FROM SENATOR SESSIONS ON BEHALF OF CONSTITUENT RE BRAKE FAILURES ON HIS MOTORHOME (DOT/I#2010-1141)*TGW 2001 WORKHORSE W22 CHASSIS. THE CONSUMER STATED THE FIRST TIME HE LOST BRAKING HE WAS DESCENDING A NARROW TWISTING MOUNTAIN ROAD. THE CONSUMER WAS ABLE TO BRING THE RV TO COMPLETE AND SAFE STOP USING THE HAND BRAKE AND DOWNSHIFTING. THE CONSUMER DISCOVERED THE FRONT WHEEL WAS SMOKING AND NEARLY CAUGHT ON FIRE. THE RV WAS TOWED THE NEXT DAY, TO THE NEAREST WORKHORSE FACILITY. THE DEALER REPLACED ALL THE BURNED PARTS, WHICH INCLUDED THE CALIPERS, ABS SENSORS, PIN KIT, ROTOR, OIL SEALS AND PADS. WORKHORSE WAS AWARE OF THE DESIGN PROBLEM IN THE BRAKES RELATED TO A TYPE OF PLASTIC INSTEAD OF STEEL COMPONENT IN THE CALIPER PISTONS THAT EXPANDED WITH HEAT WHICH PREVENTED THE BRAKE FROM RELEASING FROM THE BRAKING POSITION. IN JANUARY 2004, THE CONSUMER AGAIN LOST BRAKING ABILITY, NARROWLY AVOIDING A REAR END COLLISION WITH AN 18 WHEELER BY SWERVING INTO THE EMERGENCY LANE. AGAIN, THE RV WAS TO TOWED THE DEALER. UPON INSPECTION, THEY DETERMINED BOTH REAR CALIPERS HAD STUCK WHICH CAUSED OVERHEATING OF THE BRAKE FLUID TO A GEL. THE CONSUMER STATED AT LEAST THREE TIMES, THE BRAKES HAVE OVERHEATED DUE TO STUCK CALIPERS REQUIRING REMOVAL OF THE WHEELS AND LUBRICATING THE CALIPER PINS. IT WASN'T UNTIL JULY 2005, TWO YEARS AFTER THE CONSUMER EXPERIENCED A NEAR FATAL ACCIDENT DUE TO BRAKE FAILURE, THAT WORKHORSE SENT HIM COPY OF A DEALER BULLETIN 50401-C DESCRIBING A DEFECT INVOLVING BRAKE CALIPER HANGING IN A PARTIAL APPLY POSITION THAT CAN GET EXTREMELY HOT CAUSING SEVERE DAMAGE TO BRAKE PARTS. WORKHORSE HAS DENIED THE CONSUMER REIMBURSEMENT TWICE. *JB UPDATED 09/09/11. *JB

NHTSA ID

10335953

Incident

Jul 11, 2003

TL*THE CONTACT OWNS A 2001 WORKHORSE W22. WHILE DRIVING 30 MPH WHEN HE TRIED TO STOP AT A RED LIGHT HIS BRAKES DID NOT WORK. THE CONTACT CONTINUED TO APPLY PRESSURE TO THE BRAKES AND THE VEHICLE STILL WOULDN'T SLOW DOWN. HE PULLED INTO A STORE PARKING LOT WERE HE FINALLY GOT THE VEHICLE TO STOP. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 27,000 AND THE CURRENT MILEAGE WAS 28,000.

NHTSA ID

10313636

Incident

Jun 1, 2009

Mileage

27,000 mi

2001 WORKHORSE CHASSIS WITH BOSCH 4 WHEEL DISC BRAKES. COMPLETE SYSTEM REPLACED ONE TIME AT OWNERS EXPENSE. SINCE REPLACEMENT, THERE HAVE TWO INCIDENTS OF TOTAL BRAKE FAILURE WHICH COULD HAVE CAUSED A TERRIBLE CRASH HAD THERE NOT BEEN A DITCH TO RUN INTO. THE COACH IS A MONACO. MONACO NO LONGER EXISTS AND WORKHORSE AND BOSCH GO BACK AND FORTH ABOUT WHO IS AT FAULT AND NO ONE WILL FIX THE PROBLEM. MY FAMILY AND I ARE IN DANGER EVERY TIME WE CHOOSE TO USE THE MOTORHOME. *TR

NHTSA ID

10279090

Incident

Sep 20, 2008

Mileage

49,000 mi

FOUR WHEEL BRAKE FAILURE WITH CRACKED ROTORS AND REPLACEMENT OF ROTORS, PADS, AND CALIPERS REQUIRED. *TR

NHTSA ID

10215444

Incident

Mar 9, 2006

Mileage

27,000 mi

WE HAVE A 2001 WINNEBAGO ADVENTURER CLASS A MOTORHOME ON A WORKHORSE W22 CHASSIS. I AM WRITING REGARDING THE ABS BRAKING SYSTEM. IN AUGUST 2004, WHILE DRIVING, IT FELT LIKE THE RV WAS GETTING A FLAT TIRE. WE PULLED OVER AND FOUND NO EVIDENCE OF THAT. ALL THE INSTRUMENT LIGHTS AND GAUGES WERE WORKING PROPERLY AND NO WARNING LIGHTS. ON CONTINUING DOWN THE HIGHWAY, I NOTICED THAT WHEN I APPLIED THE BRAKE, IT WOULD STEER TO THE RIGHT QUITE NOTICEABLY, AND THERE WAS ALSO A SMELL OF BURNING PLASTIC. THE MECHANIC REPLACED THE LEFT FRONT CALIPER, THE MELTED ABS SENSOR AND THE CRACKED ROTOR DUE TO EXCESSIVE HEAT. I CALLED WORKHORSE AND THEY HAD NO BRAKE, SENSOR OR ROTOR PROBLEMS REPORTED. WE USED OUR EXTENDED WARRANTY. THE TOTAL BILL WAS $1,252.67. WARRANTY PAID $356.68 AND WE PAID $895.99. THE RV HAD 19,335 MILES. SINCE THEN WE HAVE READ OF A COUPLE OF PEOPLE WITH SIMILAR BRAKE SENSOR PROBLEMS, AND TALKED WITH A CAMPER WHO HAD REPLACED THE FRONT BRAKE PADS THREE TIMES IN LESS THAN 20,000 MILES ON WORKHORSE CHASSIS. I AM BEGINNING TO THINK THAT THIS IS NOT AN ISOLATED INCIDENT AND MAYBE THERE SHOULD BE A RECALL. THERE WAS EVIDENTLY SOME MALFUNCTION FOR THE ABS LIGHT NOT TO GIVE US A WARNING WHEN I CHECKED THE DASHBOARD. WE HAVE BRAGGED ON THE WORKHORSE CHASSIS TO SO MANY OF OUR FRIENDS AND HAVE BEEN REALLY PLEASED WITH ITS PERFORMANCE UP TO THIS POINT. I WOULD LIKE TO THINK THAT WORKHORSE WOULD CHECK INTO THE PROBLEM AND REIMBURSE US AND THE WARRANTY CO.*AK

NHTSA ID

10096447

Incident

Aug 19, 2004

Mileage

19,335 mi