2001 Workhorse W22

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 MOTORHOME CHASSIS EQUIPPED WITH BOSCH ZOPS, THE PADS CAN DRAG ON THE ROTOR SURFACE DUE TO THE PIN SLIDE.

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.

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.

Defect. VEHICLE DESCRIPTION: MOTOR HOME AND COMMERCIAL CHASSIS. THE REAR AXLE U-BOLTS MAY NOT BE TIGHTENED CORRECTLY DUE TO RANDOM FAILURE OF PRODUCTION TOOLING IN THE SPECIFIED TIME SPAN.

Risk. LOW U-BOLT TORQUE CAN RESULT IN U-BOLTS COMING LOOSE AND NOT PROPERLY RETAINING THE REAR AXLE TO THE VEHICLE, RESULTING IN A LOSS OF VEHICLE CONTROL.

Remedy. DEALERS WILL TIGHTEN THE REAR AXLE U-BOLTS. OWNER NOTIFICATION IS EXPECTED TO BEGIN OCTOBER 10, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT WORKHORSE AT 1-877-946-7731.

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.

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.

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

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

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.

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

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

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

DEALERSHIP WAS UNABLE TO PERFORM THE BOSCH ZOPS BRAKE CALIPER 04V084000 RECALL REPAIRS BECAUSE THE PARTS WERE NOT AVAILABLE FOR A MONTH.*AK

WE HAVE A 2001 DUTCHSTAR CLASS A MOTORHOME, BUILT ON WORKHORSE CHASSIS NUMBER 28321. I AM WRITING FOR A NUMBER OF REASONS. THE FIRST BEING THAT I AM REQUESTING INFORMATION ON POSSIBLE RECALLS THAT INCLUDE THIS UNIT. I UNDERSTAND THAT THERE ARE TWO CAMPAIGNS FOR THE 2001 WORKHORSE CHASSIS, NHTSA # 04V084000, HAVING TO DO WITH SERVICE BRAKES, HYDRAULIC AND # 01V317000, HAVING TO DO WITH SUSPENSION:REAR:SPRINGS:LEAF SPRING ASSEMBLY:U-BOLT, LEAF SPRING TO AXLE. I WOULD LIKE TO KNOW WHETHER OUR UNIT IS INCLUDED AND IF SO, WHY WE WERE NOT NOTIFIED. THE SECOND REASON I AM WRITING HAS TO DO WITH THE ABS BRAKE SENSORS ON THE FRONT WHEELS. IN OCTOBER OF 2003, WE HAD TO HAVE THE RIGHT BRAKE SENSOR REPLACED AFTER IT HAD BURNED UP WITH ONLY 13,523 MILES ON THE UNIT. ON JULY 6, 2004, BOTH FRONT ABS BRAKE SENSORS BURNED UP AND REQUIRED REPLACING WITH ONLY 16,367 MILES. LUCKILY, WE WERE TRAVELING AT A LOW SPEED AS THE LACK OF THE SENSORS APPARENTLY CAUSED BOTH FRONT BRAKES TO LOCK UP, WHICH COULD HAVE BEEN EXTREMELY DANGEROUS HAD WE BEEN TRAVELING ON THE HIGHWAY INSTEAD OF A CITY STREET. WHILE I REALIZE THAT THE UNIT IS OUT OF THE 3 YEAR WARRANTY, THIS APPEARS TO BE A MANUFACTURERS DEFECT WHEN THE SAME UNITS BURN UP WITHIN 3000 MILES. I HAVE ALSO SPOKEN TO A FRIEND THAT HAS A 2002 W22 CHASSIS AND SHE HAS HAD THE SAME PROBLEM, CAUSING HER TO REPLACE BOTH FRONT SENSORS. THESE SENSORS SHOULD BE DESIGNED TO LAST A LOT MORE THAN 16,000 MILES AND CERTAINLY MORE THAN 3,000 MILES. I FEEL THAT WORKHO