2004 Workhorse W22 Brakes Problems

The contact owns a 2004 Workhorse W22. The contact stated that after the RV was stored for several years, the contact learned that the brakes had seized. The contact then became aware that the RV was included in a recall. The RV was taken to the dealer and repaired under NHTSA Campaign Number: 09V110000 (Service Brakes, Hydraulic) however, the RV experienced brake failure. The contact stated that after the repair due, to personal issues, he was unable to use the RV for several months. The contact stated that he recently started driving the RV around the property and locally; however, he became aware of brake fluid leaking underneath the RV. There was no warning light illuminated. The contact had not taken the RV to the dealer. The manufacturer was not made aware of the failure. The approximate failure mileage was 23,022.

NHTSA ID

11530594

Incident

Apr 13, 2023

Mileage

23,022 mi

The contact owns a 2004 Workhorse W22 RV. The contact stated while driving approximately 60 MPH, the brakes heated up and seized. The contact stated that the ABS warning light was illuminated. The contact pulled over and smelled a burning odor. The contact stated that he waited for over one hour for the brakes to cool and then he continued driving to his destination. The contact stated that the failure became constant and he no longer took the RV on long trips. The contact had taken the RV to an independent mechanic where it was diagnosed and determined that the calipers, pistons, sensors, and rotors needed to be replaced. The RV had been repaired; however, the failure reoccurred. The manufacturer had not been informed of the failure. The failure mileage was approximately 60,000.

NHTSA ID

11486858

Incident

Jun 28, 2018

Mileage

60,000 mi

The contact owns a 2004 Newmar Kountry built on a 2004 Workhorse W22 chassis. The contact stated while driving 70 MPH, the brake pedal was depressed but failed to respond as needed. The contact was able to continue driving. The vehicle was taken to an independent mechanic on four occasions where the brake pads were replaced four times however, the failure persisted. The contact stated while driving on a wet road surface and attempting to make a stop at the stop sign, the vehicle slid into a ditch. The contact did not sustain any injuries. The contact was able to pull the RV out of the ditch with the assistance of a four-wheel drive vehicle. The contact’s friend, an independent mechanic, arrived at the scene and diagnosed that the brake calipers had seized, causing the brakes to overheat while driving. Additionally, the independent mechanic diagnosed that the brake rotors needed to be replaced. The mechanic performed an unknown service on the brakes which allowed the contact to drive to his residence. However, the failure reoccurred and the brake pedal was smoking. The contact became aware that the VIN was included in NHTSA Campaign Number: 09V110000 (Service Brakes, Hydraulic). The manufacturer was notified of the failure and referred the contact to the dealer for assistance. The dealer informed the contact that they needed to verify that the manufacturer would cover the recall repair prior to assisting. The contact contacted other unknown dealers who declined to assist. The vehicle was not repaired. The failure mileage was approximately 30,000.

NHTSA ID

11483385

Incident

Sep 7, 2020

Mileage

30,000 mi

2004 CHEVROLET GULF STREAM. CONSUMER WRITES IN REGARDS TO BRAKE SYSTEM RECALL REPAIR ISSUES - RIGHT FRONT CALIPER/ABS SENSOR REPLACEMENTS. *SMD *TR

NHTSA ID

10917053

Incident

Dec 28, 2015

Mileage

21,960 mi

2000 MILES AFTER RECALL WAS FIXED WHEN BRAKES APPLIED STEERING WHEEL PULLS YOUR HANDS OFF AND GOES TO THE RIGHT AND CANT KEEP IT IN THE ROAD.

NHTSA ID

10884014

Incident

Jun 20, 2016

Mileage

17,000 mi

TL* THE CONTACT OWNS A 2004 WORKHORSE W22 CHASSIS MOTORHOME. THE CONTACT STATED THAT WHILE TRAVELING APPROXIMATELY 15 MPH, THE BRAKES FAILED AND THE PEDAL SANK TO THE FLOOR. THE CONTACT HAD TO APPLY THE EMERGENCY BRAKE IN ORDER TO STOP THE VEHICLE. THE AUTHORIZED DEALER WAS NOT ABLE TO PROVIDE A REMEDY. THE VEHICLE WAS NOT REPAIRED. THE CONTACT WAS NOT NOTIFIED OR INCLUDED IN RECALL NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 19,870.

NHTSA ID

10639041

Incident

Jul 1, 2014

Mileage

19,870 mi

TL* THE CONTACT OWNS A 2004 FLEET WOOD MOTOR HOME EQUIPPED WITH A WORKHORSE W22 CHASSIS. THE CONTACT STATED THAT WHILE DRIVING 45 MPH, THE VEHICLE STARTED TO DECELERATE. AFTER INSPECTING THE VEHICLE, HE NOTICED THAT THE REAR BRAKES WERE ON FIRE. THE CONTACT WAS ABLE TO CONTAIN THE FIRE BY USING AN EXTINGUISHER. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE TECHNICIAN VERIFIED THAT THE BRAKES FAILED AND THE BRAKES, ROTOR, BRAKE CALIPER, SPEED SENSOR AND THE BRAKE LINES WOULD NEED REPLACING. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 23,000.

NHTSA ID

10545708

Incident

Sep 11, 2013

Mileage

23,000 mi

TL* THE CONTACT OWNS A 2004 GEORGI BOY CRUSE MASTER RV EQUIPPED WITH A 2004 WORKHORSE W22 CHASSIS. THE CONTACT WAS DRIVING APPROXIMATELY 55 MPH WHEN THE BRAKE PEDAL WAS ENGAGED AND THE VEHICLE FAILED TO DECELERATE. THE CONTACT WAS ABLE TO REDUCE SPEED AFTER APPLYING THE BRAKES REPEATEDLY AND TO A COMPLETE STOP. AFTER THIRTY MINUTES THE VEHICLE RESUMED NORMALLY. THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER A NHTSA CAMPAIGN ID NUMBER: 09V193000 (SERVICE BRAKES, HYDRAULIC). THE FAILURE RECENTLY RECURRED AND THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 12,000...UPDATED 05/16/13 *BF THE CONSUMER STATED THE BREAKS AND ROTORS SHOULD HAVE BEEN CHANGED. THEY WERE WARPED FROM THE EXCESSIVE HEAT CAUSED BY CALIPERS HANGING UP. UPDATED 05/23/2013 *JS

NHTSA ID

10504526

Incident

Sep 28, 2006

Mileage

12,000 mi

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

NHTSA ID

10434590

Incident

Sep 1, 2007

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

NHTSA ID

10397748

Incident

Apr 10, 2011

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

NHTSA ID

10378882

Incident

Aug 24, 2010

TL*THE CONTACT OWNS A 2004 FLEETWOOD BOUNDER. THE CONTACT STATED THAT THE WHEN THE BRAKES WERE ENGAGED THEY WOULD SURGE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO STATED THAT THE REAR ROTORS NEEDED TO BE SERVICED AGAIN. THE MANUFACTURER WAS CONTACTED AND THEY WERE NOT WILLING TO OFFER ANY ASSISTANCE BECAUSE THE VEHICLE WAS NOT UNDER WARRANTY. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 696 AND THE CURRENT MILEAGE WAS 35,000. UPDATED 3/7/11 *CN UPDATED 03/14/11

NHTSA ID

10378801

Incident

May 10, 2004

Mileage

694 mi

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

NHTSA ID

10379068

Incident

Nov 10, 2010

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

NHTSA ID

10375852

Incident

Jan 3, 2011

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

NHTSA ID

10375777

Incident

Jun 26, 2010

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

NHTSA ID

10374508

Incident

Jan 3, 2011

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

NHTSA ID

10373127

Incident

Sep 1, 2010

TL*THE CONTACT OWNS A 2004 FLEETWOOD SOUTHLAND MOTOR HOME WITH A 2004 WORKHORSE W22 CHASSIS. RECALL NHTSA#09V198000; SERVICE BRAKES, AIR WHICH WAS RELATED TO THE CALIPERS THAT WERE CRACKED, OVER HEATING AND STICKING. THE FAILURE ALSO CAUSED THE ROTORS TO CRACK WHICH RENDERED THE VEHICLE UNDRIVABLE. AFTER THE DEALER REPLACED THE CALIPERS THEY FOUND ADDITIONAL DAMAGE ON THE ROTORS. THE CONTACT WAS BILLED DOUBLE TO REPAIR THE ADDITIONAL BRAKE DAMAGE WHICH SHOULD BE A PART OF THE RECALL. THE MANUFACTURER WAS CONTACTED AND STATED THAT THEY WOULD NOT REPLACE THE ROTORS BECAUSE THEY WERE NOT COVERED BY THE WARRANTY. THE CONTACT WAS RESPONSIBLE FOR THE REPAIR COST. THE FAILURE MILEAGE WAS 24,127.

NHTSA ID

10365257

Incident

Nov 1, 2010

Mileage

24,127 mi

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

NHTSA ID

10344397

Incident

Apr 1, 2009

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

NHTSA ID

10356412

Incident

Sep 8, 2008

TL* THE CONTACT OWNS A 2005 THOR WINDSPORT MOTOR HOME WITH A 2004 W22 WORKHORSE CHASSIS. THE CONTACT STATED SHE RECEIVED NOTIFICATION OF AN UNKNOWN RECALL FOR THE BRAKES OF THE WORKHORSE CHASSIS. THE DEALER ADVISED THAT THERE WERE NO REPLACEMENT PARTS AVAILABLE TO MAKE REPAIRS ON THE VEHICLE. THE MANUFACTURER CONFIRMED THAT THE PARTS WERE NOT AVAILABLE ABD COULD NOT PROVIDE A TIME WHEN THEY WOULD BECOME AVAILABLE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

10350598

Incident

May 12, 2009

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.

NHTSA ID

10349210

Incident

Apr 1, 2009

Mileage

16,000 mi

TL* THE CONTACT OWNS A 2004 CRUISE MASTER GEORGIE BOY EQUIPPED WITH A WORKHORSE CHASSIS W22. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 35 MPH, APPROACHING A COMPLETE STOP THE ANTI-LOCK BRAKE SYSTEM WARNING LIGHT ILLUMINATED. SUDDENLY, DURING BRAKING THE BRAKE PEDAL BECAME SPONGY AND TRAVELED TO THE FLOOR WITHOUT RESISTANCE. THE CONTACT BEGAN TO PUMP THE BRAKE PEDAL NUMEROUS TIMES BEFORE THE BRAKE PEDAL RELEASED TO NORMAL POSITION. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND INSPECTED. THE CONTACT DETECTED THE MASTER CYLINDER EXHIBITED BRAKE FLUID LEAKAGE. THE CONTACT DISPENSED BRAKE FLUID INTO THE MASTER CYLINDER RESERVOIR AND RESUMED OPERATION. ALSO, ON A SEPARATE OCCASION THE BRAKE CALIPERS LOCKED UP WITHOUT WARNING. THE MANUFACTURER WAS NOTIFIED OF THE DEFECTS AND THEY ACCEPTED THE FINANCIAL RESPONSIBILITY FOR REPLACEMENT OF THE BRAKE CALIPERS AND ABS SENSOR. THE VEHICLE WAS REPAIRED AND THE FAILURES CONTINUED. THE VEHICLE WAS BEING DIAGNOSED AT THE TIME OF THE COMPLAINT. THERE WAS A RECALL UNDER NHTSA CAMPAIGN ID NUMBER 09V110000 (SERVICE BRAKES, HYDRAULIC). HOWEVER, THE RECALL PART HAD BEEN UNAVAILABLE FOR OVER ONE YEAR. THE FAILURE MILEAGE WAS APPROXIMATELY 36,000.

NHTSA ID

10342928

Incident

Apr 14, 2010

Mileage

36,000 mi

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

NHTSA ID

10334894

Incident

Apr 1, 2008

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

NHTSA ID

10331711

Incident

Apr 21, 2010

Mileage

26,456 mi