2004 Workhorse W20

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.

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.

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.

Defect. ON CERTAIN MOTOR HOME AND TRUCK CHASSIS EQUIPPED WITH GENERAL MOTORS 8.1L V8 ENGINES, IMPROPER HARDENING DURING THE HEAT TREATMENT PROCESS CAN CAUSE THE FUEL RAIL PULSE DAMPER RETAINER CLIP TO FRACTURE, RESULTING IN INADEQUATE RETENTION OF THE DAMPER. IF THE DAMPER BECOMES LOOSE, FUEL COULD BE PUMPED BY THE FUEL PUMP INTO THE UNDER HOOD AREA.

Risk. IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.

Remedy. DEALERS WILL REPLACE THE FUEL RAIL PULSE DAMPER RETAINER CLIPS ON THESE ENGINES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 1, 2006. OWNERS MAY CONTACT WORKHORSE AT 877-294-6773.

WE DO NOT FEEL THAT THE INSTRUMENT PANEL CLUSTER ON OUR MOTORHOME HAS EVER BEEN LARGE ENOUGH OR CLEAR ENOUGH FOR EASY READING. WE HAVE ALWAYS BEEN UNHAPPY WITH THE VISIBILITY AND JUST RECENTLY THE TRANSMISSION INDICATORS FOR 3 AND 1 GEAR HAVE FADED COMPLETELY. AT PRESENT WE HAVE AN APPOINTMENT TO GET THE PANEL REPLACED. *TR

WHILE DRIVING ON US441 NEAR TAVARES FL GOT A WARNING LIGHT FOR ANTI LOCK BRAKES. PULLED OVER INTO A SHOPPING AREA. LEFT FRONT WHEEL AND RIGHT REAR DUAL WHEEL WERE HOT. RESTARTED ENGINE GOT A BRAKE FAILURE WARNING ON DASH MESSAGE CENTER. LET BRAKES COOL FOR APPROXIMATELY 90 MINUTES. DROVE HOME THEN TO WORKHORSE REPAIR CENTER WITHOUT FURTHER TROUBLE. COURTESY CHEVROLET REPLACED 4 ROTORS 4 CALIPERS 2 ANTI LOCK SENSOR AND REPLACED BRAKE FLUID. *TR

ON 9/6/07, THE L.F. BRAKE ON MY MOTORHOME SEIZED UP AND OVERHEATED THE BRAKE ROTOR FOR ALMOST 10 MILES UNTIL I NOTICED SEVERE SHAKING IN THE STEERING WHEEL & SMELLED "BURNT BRAKE LINING" WHEN I STOPPED. I WAS DRIVING IN NORMAL CITY TRAFFIC NEAR ALLIANCE, OHIO; -NOT EXCESSIVE STOP AND GO, BUT THERE WAS MAYBE 4 RED LIGHTS OVER THE COURSE OF 3 MILES DISTANCE (AT 30 MPH) TO STOP. MY STOPPING WAS "NORMAL", NOT SUDDEN OR ERRATIC. THE LEFT FRONT HUB & WHEEL GOT SO HOT FROM THE CALIPER/BRAKE ASSY. SEIZING THAT IT BOILED AWAY ALL OF THE 90W LUBE ON THE WHEEL BEARINGS AND BLEW OUT THE RUBBER PLUG ON THE LUBE SIGHT GLASS. I LET IT COOL DOWN FOR AN HOUR, THEN LOOKED AT THE INNER SIDE OF THE L.F. WHEEL TO SEE IF I'D HAVE TO LOOSEN/PRY AWAY THE SEIZED BRAKE PAD OR CALIPER ASSEMBLY. SURPRISE, THE BRAKE PADS WERE ALREADY SITTING BACK AWAY FROM THE ROTOR; -THE CALIPER HAD APPARENTLY RETRACTED BY ITSELF AFTER COOLING DOWN. I PROCEEDED SLOWLY TO THE CAMPGROUND, 5 MILES AWAY, AND MADE ARRANGEMENTS TO GET SOME 90W LUBE OIL. LUBE WAS REPLACED THE NEXT DAY AND THE WHEEL BEARINGS STILL FELT GOOD; ANOTHER SIGHT CAP SEAL WAS INSTALLED. ON 9/12/07, I TOOK THE COACH TO MAINLINE TRUCK & TRAILER (A WORKHORSE CHASSIS SERVICE DEALER) IN SOLON, OHIO, FOR SERVICE. IN A NUTSHELL, I ENDED UP PAYING $828.28 TO REPAIR THE DAMAGE AND SERVICE MY COACH FOR FUTURE "PEACE OF MIND". THE FOLLOWING WORK WAS PERFORMED: SERVICED ALL CALIPER SLIDE PINS, LUBE, & BOOTS ON ALL 4 WHEELS; CONFIRM CORRECT CALIPER OPERATION ON ALL

THE BRAKES WERE FADING SO I HAD THEM INSPECTED BY LES SCHWAB TIRES. THEY INFORMED ME THAT ALL 4 ROTORS HAD CRACKS IN THEM AND THEY WERE A SAFETY ISSUE. I HAVE ABOUT 30,000 MILES ON THE 2004 SOUTHWIND MOTORHOME WORKHORSE CHASIS. I AM RESPONDING TO NHTSA ACTION NUMBER: EA07016. *TR

RIGHT FRONT DISC BRAKE OVERHEATED AND CAUSED OIL SEAL FAILURE RESULTING IN CONTAMINATION OF DISC BRAKE LINING CONTAMINATION AND REDUCED BRAKE EFFECTIVENESS. *TR

THIS IS A BRAKE FAILURE ON ,MY 2004 ALLEGRO MOTORHOME BUILT ON A W-20 CHASSIS MANUFACTURED BY WORKJORSE CUSTOM CHASSIS. ON THE DATE IN QUESTION, THE RIGHT REAR BRAKE LOCKED UP AND OVERHEATED. THE LEFT REAR BRAKE OVERHEATED. THESE ACTIONS CAUSED REPLACEMENT OF THE RIGHT REAR CALIPER, ROTER, SEALS AND SLIDE PINS. THE CALIPER AND SLIDE PINS WERE REPLACED ON THE LEFT REAR BRAKE. THE CALIPERS AND SLIDE ON BOTH FRONT BRAKES WERE REPLACED DUE TO OVERHEATING. OLD PARTS ARE AVAILABLE FOR INSPECTION. THE WORK WAS PERFORMED AT AN AUTHORIZED WORKHORSE SERVICE CENTER AND THE COAST CAN BE PROVIDED UPON REQUEST

DRIVING RV NORMALLY ABOUT 40 MPH WHEN REQUIRED TO STOP. BRAKE PEDAL WENT TO THE FLOOR. PUMPED VIGOROUSLY AND GOT A SMALL AMOUNT OF PEDAL. WHEN UNIT COOLED, WAS ABLE TO DRIVE SLOWLY FOR REPAIR. LEFT REAR ROTOR WAS SCORED AND THE CALIPER WAS STICKING, CAUSING THE BRAKE FLUID TO BOIL. *JB UPDATED 12/12/07 *BF UPDATED 12/12/07 *TR