RoadVitals

2002 Workhorse W22

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
67
Latest Mar 23, 2023
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
2
Latest Apr 3, 2009
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
2
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
7

Overview

Our database contains 67 NHTSA owner-reported complaints for the 2002 Workhorse W22, most frequently naming the brakes, engine and suspension categories. 2 safety recalls have been issued covering this model year; and 2 NHTSA investigations name it.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Brakes6484.2%
  • Engine45.3%
  • Suspension22.6%
  • Exterior lighting11.3%
  • Other / unspecified11.3%
  • Transmission11.3%
  • Visibility11.3%
  • Driver assistance11.3%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

2 campaigns cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
09V110000

SERVICE BRAKES, HYDRAULIC

Apr 3, 2009
48,876 units potentially affected
The defect: 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.
The risk: 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.
The remedy: 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.
NAVISTAR, INCManufacturer number 50901-C & 51101-CView on NHTSA.gov
04V084000

SERVICE BRAKES, HYDRAULIC

Feb 18, 2004
10,235 units potentially affected
The defect: ON CERTAIN MOTORHOME CHASSIS EQUIPPED WITH BOSCH ZOPS, THE PADS CAN DRAG ON THE ROTOR SURFACE DUE TO THE PIN SLIDE.
The risk: A HANG UP OR LOCK UP MAY CAUSE THE CALIPERS TO OVER HEAT AND NOT ALLOW THE DRIVER TO STOP SAFELY. THIS COULD CAUSE OVERHEATING OF THE BRAKE CALIPERS WHICH COULD RESULT IN A VEHICLE FIRE.
The remedy: DEALERS WILL INSPECT, REPAIR AND REPLACE ACCORDING TO THE PROCEDURE DEVELOPED BY BOSCH (SEE CAMPAIGN 03E064000). THE RECALL BEGAN ON AUGUST 1, 2004. OWNERS SHOULD CONTACT WORKHORSE AT 1-877-294-6773.
WORKHORSE CUSTOM CHASSISManufacturer number 50401-CView on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

EA07016ClosedEngineering Analysis

OVERHEATING DISC BRAKE CALIPER

Opened Nov 16, 2007
Closed Aug 19, 2009

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.

SERVICE BRAKES, HYDRAULICLed to recall 09V110000
EA03003ClosedEngineering Analysis

OVERHEATING FRONT AND REAR BRAKES

Opened Apr 9, 2003
Closed Mar 3, 2004

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.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTSLed to recall 04V019000

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

View all 67
Brakes
Filed Mar 23, 2023

The contact owns a 2002 Workhorse W22 Chassis. The contact stated that while driving at an undisclosed speed, the brake pedal went to the floorboard while depressed. Additionally, the ABS warning light was illuminated. The contact related the failure to NHTSA Campaign Number: 09V110000 (Service Brakes, Hydraulic). The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 21,000.

NHTSA ID
11513439
Incident
Mar 18, 2023
Mileage
21,000 mi
Brakes
Filed Jan 28, 2021

WE JUST PURCHASED THIS MOTORHOME AND DURING MY INVESTIGATION FOR VARIOUS REPAIRS FOUND THERE WERE 2 RECALLS ON THIS COACH. ONLY 1ST OF THE 2 OF THE RECALLS WAS ADDRESSED WITH THE 2ND RECALL BEING A MORE INTENSE MODIFICATION OF THE 1ST. I AM NOW TRYING TO FIND OUT HOW TO GET THE 2ND RECALL IMPLEMENTED SINCE NAVISTAR ABSORBED WORKHORSE AND NAVISTAR HAS BOTH CHANGED THEIR BUSINESS MODEL AND IS NOW SEEKING A BUYER. SOMEHOW, SOME WAY, THE LIABILITY OF INSURING ALL REPAIRS ARE COMPLETED RESTS WITH SOMEONE. THANKS FOR YOUR HELP IN GIVING ME SOME DIRECTION TO GET THIS RESOLVED. 😀 MARK EGAN*DT*JB

NHTSA ID
11390462
Incident
Jan 19, 2021
Visibility
Filed Aug 2, 2019

1) THE MANUFACTURE, WINNEBAGO INDUSTRIES, EQUIPPED THE DRIVER "COCKPIT" OF THE VEHICLE WITH THERMOPANE WINDOWS WITH AN IDENTIFIED WEAKNESS. THE SEALS IN THE WINDOWS ARE INADEQUATE TO MAINTAIN SEAL INTEGRITY, THUS ALLOWING AIR INFILTRATION. SAID AIR INFILTRATION CAUSED FOGGING OF THE GLASS, AND AN ACCUMULATION OF CONDENSATION WITHIN THE GLASS. THE FRONT "COCKPIT" WINDOWS ON BOTH SIDES BECAME SO FOGGED OVER AND DIRTY IN BETWEEN THE WINDOWS, THE DRIVER WAS UNABLE TO SEE OUT. THIS WAS A PARTICULAR SAFETY ISSUE WHEN PASSING. THE DRIVER CANNOT SEE INTO THE PASSENGER SIDE MIRROR TO SAFELY PULL BACK INTO THE DRIVING LANE. NOR COULD THE MIRRORS BE USED WHILE DRIVING OR IN REVERSE. THE REPLACEMENT OF THESE SMALL "COCKPIT" WINDOWS WAS TO THE TUNE OF $500 PER WINDOW. ALSO, REPLACEMENT DOES NOT EQUAL ORIGINAL MANUFACTURE SO NOW THE WINDOWS "WHISTLE" WITH CERTAIN WIND DIRECTIONS WHILE DRIVING. THIS IS QUITE ANNOYING TO LISTEN TO WHILE DRIVING. LG

NHTSA ID
11241386
Incident
Aug 30, 2017
Brakes
Filed Jul 15, 2019

TL* THE CONTACT OWNS A 2002 WORKHORSE W22. THE CONTACT STATED THAT THE ABS WARNING INDICATOR FLASHED AND REMAINED ILLUMINATED. IN ADDITION, THE BRAKE PEDAL WAS DEPRESSED AND TRAVELED TO THE FLOORBOARD, CREATING THE RISK OF A POTENTIAL CRASH. THE CONTACT HAD TO APPLY FORCE TO THE BRAKE PEDAL TO STOP THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 04V084000 (SERVICE BRAKES, HYDRAULIC) AND 09V110000 (SERVICE BRAKES, HYDRAULIC); HOWEVER, THE VEHICLE EXHIBITED THE SAME FAILURE LISTED IN THE RECALL CAMPAIGNS. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS NOT AVAILABLE. *BF CONSUMER STATED RECALL TAKING CARE OF BY WORKHORSE. *JB

NHTSA ID
11232052
Incident
Jul 1, 2019
Brakes
Filed Mar 25, 2011

2002 DAMON INTRUDER ON A 2002 WORKHORSE W22 CHASSIS. CONSUMER STATES DEFECTIVE CALIPERS AND SEEKS REIMBURSEMENT FOR REPAIRS *TGW THE CONSUMER STATED THE ROTORS, SEALS, PADS AND HOSES ALSO HAD TO BE REPLACED. THE CONSUMER BELIEVED THE DEFECTIVE CALIPERS CAUSED DAMAGE TO THE OTHER BRAKE COMPONENTS. *JB

NHTSA ID
10393224
Incident
Feb 25, 2011
Brakes
Filed Mar 25, 2011

NON-AVAILABILITY OF PARTS, NHTSA RECALL # EA02035. I HAVE TRIED TO MAKE AN APPT W/AN AUTHORIZED WORKHORSE CHASSIS SERVICE CENTER. THE TWO CENTERS NEAREST ME HAVE HAD THE CALIPER KITS ON ORDER FOR THE LONGEST TIME. I FEEL THAT WORKHORSE CUSTOM CHASSIS IS DRAGGING THEIR FEET WHEN SUPPLYING THE SERVICE CENTERS. *TR

NHTSA ID
10392929
Incident
Sep 1, 2010
Mileage
14,000 mi
Brakes
Filed Jan 21, 2011

2002 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO PROBLEMS WITH WORKHORSE BRAKES AND REQUESTS REIMBURSEMENT *TGW THE CONSUMER STATED THE FIRST PROBLEM HE ENCOUNTERED WITH THE RV WAS THE SMELL OF BURNING BRAKES WHICH WAS NOTICED IN 2004 AND THE REPAIRS WERE DONE DURING THE BOSCH BRAKE CALIPER RECALL. THE NEXT PROBLEM CAME IN LATE 2007 WHEN THE CONSUMER STARTED EXPERIENCING BRAKE FAILURE AND THE ABS LIGHT ILLUMINATED. THE CALIPERS, ROTORS AND ABS REPAIRS WERE COMPLETED AT A COST OF $3700. THE EXTENDED WARRANTY COVERED ROUGHLY HALF THE COST, BUT THE CONSUMER HAD TO PAY OVER $1800. THE DENIAL LETTER WORKHORSE SENT THE CONSUMER, STATED THE WORK THAT WAS PERFORMED IN 2004 SHOWED NO ISSUES IN REGARDS TO WORKMANSHIP OR MATERIAL DEFECTS *JB

NHTSA ID
10377848
Incident
Jan 3, 2011
Brakes
Filed Jan 20, 2011

2002 WORKHORSE W22 CHASSIS. CONSUMER IS SEEKING REIMBURSEMENT FOR A TOWING BILL DUE TO PROBLEMS WITH WORKHORSE CUSTOM CHASSIS *TGW THE CONSUMER STATED THE BRAKES FAILED TO RELEASE WHILE DRIVING.*JB

NHTSA ID
10376211
Incident
Sep 16, 2010

Compare model years

Complaint and recall counts across every year of this model

Workhorse W22 by model year
YearComplaintsRecallsInvestigationsIssue Index
2011020—
2009200—
2008410—
2007510—
2006830—
2005213158.5
2004922152.0
20031131151.4
2002Viewing672260.8
2001103260.0
2000111—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.