2002 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.

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.

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

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

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

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

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

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

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

2003 PACE ARROW MOTORHOME ON A 2002 WORKHORSE W22 CHASSIS. CONSUMER IS REQUESTING REIMBURSEMENT FOR BRAKE CALIPER REPLACEMENT SINCE THIS WAS A RECALL ISSUE FOR WORKHORSE W22 CHASSIS. *KB THE CONSUMER STATED AFTER THE RV WAS PURCHASED, THE ABS LIGHT ILLUMINATED AND THE BRAKE PEDAL WAS SOFT. BRAKE FLUID LEAKED OUT AND THE WHEEL GREASE WAS EXTREMELY HOT. THE BRAKE LINE ALSO HAD TO BE REPLACED. *JB

TL*THE CONTACT OWNS A 2002 BOUNDER 36U RV EQUIPPED WITH A WORKHORSE CHASSIS W22. THE VEHICLE WAS TAKEN TO THE DEALER AND REPAIRED UNDER NHTSA CAMPAIGN ID NUMBER 09V110000 (SERVICE BRAKES, HYDRAULIC). THE TECHNICIAN INFORMED THAT THE FRONT AND REAR ROTORS HAD SEVERE CRACKS SO BOTH ROTORS WERE REPLACED AT THE EXPENSE OF THE OWNER. THE CONTACT STATED THAT THE RECALL REMEDY SHOULD INCLUDE THE REPLACEMENT OF THE ROTORS. THE FAILURE MILEAGE WAS 40,126. UPDATED 01/24/11 *CN

TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE CHANGING THE CALIPERS ON THE VEHICLE HE NOTICED THAT THERE WAS AN EXCESSIVE AMOUNT OF GREASE WITHIN THE MASTER CYLINDER. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE BUT HE WAS INFORMED THE ENTIRE BRAKING SYSTEM NEEDED TO BE FLUSHED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 88,000.

2002 WORKHORSE W22 CHASSIS. CONSUMER WRITES REGARDING WORKHORSE RECALL *TGW THE CONSUMER STATED HE HAS BEEN UNABLE TO GET THE NECESSARY REPAIRS MADE TO HIS RV. THE CONSUMER IS SEEKING REIMBURSEMENT FOR PREVIOUS BRAKE REPAIRS. *JB

TL*THE CONTACT OWNS A 2003 NATIONAL DOLPHIN MOTOR HOME WITH A 2002 W22 WORKHORSE CHASSIS. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHEN THE BRAKES FAILED. THE BRAKE ROTORS, BRAKE PADS AND THE SEALS WERE REPAIRED AT THE CONTACTS EXPENSE. HE RECEIVED A RECALL NOTICE ON THE CALIPERS FROM WORKHORSE BUT THE BRAKE ROTORS, BRAKE PADS AND THE SEALS HAVE FAILED AGAIN. THE DEALER STATED THAT THE WOULD ONLY REPAIR THE CALIPERS BUT NOT THE BRAKE SYSTEM; THEREFORE, THE CONTACT WOULD BE RESPONSIBLE FOR THE REPAIRS. THE DEALER CONTACTED WORKHORSE WAS WAITING FOR A RESPONSE BEFORE THEY PROCEED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 40,000. UPDATED 01/12/11*LJ THE DEALER INFORMED THE CONSUMER THE ROTORS WERE CRACKED. UPDATED 04/06/11

TL*THE CONTACT OWNS A 2002 FLEETWOOD ARROW EQUIPPED WITH A WORKHORSE W22 CHASSIS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR RECALL 04V084000 (SERVICE BRAKES, HYDRAULIC) ON OCTOBER 5, 2010. THE DEALER REPLACED THE CALIPERS AND ADVISED THE CONTACT THAT THE ROTORS AND BRAKE PADS NEEDED TO BE REPLACED AS WELL BUT WERE NOT COVERED UNDER RECALL. THE CONTACT STATED THAT THE CALIPERS CAUSED THE OTHER FAILURES AND THE MANUFACTURER SHOULD PAY FOR IT. THE CONTACT CALLED THE MANUFACTURER WHO OFFERED NO ASSISTANCE. THE CURRENT AND FAILURE MILEAGES WERE 30,840. UPDATED 01/11/11*LJ UPDATED 04/01/11

2002 WORKHORSE W22 CHASSIS. CONSUMER WRITES REGARDING BRAKE FAILURE *TGW THE CONSUMER STATED HE EXPERIENCED BRAKE FAILURE IN DECEMBER 2004. THE BRAKES WERE TEMPORARILY REPAIRED, BECAUSE ACCORDING TO THE REPAIR SHOP A RECALL WAS ISSUED, HOWEVER, THE RECALL PARTS WERE NOT AVAILABLE. IN DECEMBER 2009 THE CONSUMER RECEIVED A RECALL NOTICE REGARDING THE BRAKES. HOWEVER, WHEN HE WENT TO THE DEALER HE WAS INFORMED AGAIN THE PARTS WERE NOT AVAILABLE. IN JULY 2010, HE EXPERIENCED ANOTHER BRAKE FAILURE. THE CONSUMER WAS THEN INFORMED THE PARTS WOULDN'T BE AVAILABLE UNTIL DECEMBER 2010. SO THEREFORE, ANOTHER TEMPORARY BRAKE REPAIR WAS PERFORMED. THE CONSUMER STATED WHILE DRIVING, HE REALIZED HE HAD NO BRAKES AND HAD TO PUMP THEM TWICE IN ORDER TO STOP. THE ABS LIGHT ILLUMINATED AS WELL. THE CALIPERS AND SENSORS NEEDED TO BE REPLACED, THE WHEEL SEAL WAS LEAKING, THE ROTORS WERE DESTROYED AND THE CALIPERS BOOTS HAD MELTED. *JB

TL*THE CONTACT OWNS A 2002 FLEETWOOD SOUTHWIND RV EQUIPPED WITH A 2002 WORKHORSE W22 CHASSIS. THE CONTACT STATED THAT THE SINCE THE DATE OF PURCHASE, THE ABS LIGHT REMAINED ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS INFORMED THAT THE LIGHT DID NOT INDICATE A FAILURE AND THE VEHICLE WAS SAFE TO DRIVE. IN OCTOBER 2009, WHILE THE CONTACT WAS DRIVING 35 MPH, THE DRIVER SIDE REAR BRAKE BEGAN SMOKING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE REAR CALIPERS, CYLINDER, ROTORS AND BRAKE PADS WERE REPLACED. THE CONTACT CALLED THE MANUFACTURER AND ASKED FOR REIMBURSEMENT FOR RECALL 09V110000 (SERVICE BRAKES, HYDRAULIC) BUT WAS DENIED AND THE MANUFACTURER STATED THAT THE RECALL WAS NOT OFFICIAL AT THE TIME. THE FAILURE MILEAGE WAS APPROXIMATELY 60,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 61,000. UPDATED 12/30/10. *LJ THE CONSUMER STATED ANOTHER MOTORIST INFORMED HIM THE RIGHT REAR BRAKES WERE ON FIRE. THE CONSUMER STATED THE BRAKES LOCKED UP WHICH CAUSED A FIRE. HOWEVER, THE CONSUMER WAS ABLE TO EXTINGUISH THE FIRE.

2002 WORKHORSE CHASSIS DOLPHIN MOTORHOME. CONSUMER STATES PROBLEMS WITH THE ENGINE STALLING *TGW THE CONSUMER STATED THE RV HAS BEEN REPEATEDLY TOWED, SERVICED AND EVEN REPAIRED ONLY TO ENCOUNTER THE SAME PROBLEM. THE ENGINE WOULD SUDDENLY STALL WITH NO WARNING. WITHIN A PERIOD OF 10 SECONDS, THE POWER BRAKES AND STEERING BECAME UNRELIABLE AND THE ACCELERATOR WENT TO THE FLOOR. *JB

TL*THE CONTACT OWNS A 2002 FLEETWOOD BOUNDER WITH WORKHORSE W22 CHASSIS. WHILE DRIVING APPROXIMATELY 50-55 MPH HE ENGAGED THE BRAKES AND SMELLED THE BRAKES BURNING. HE DROVE ONTO THE EMERGENCY LANE AND ALLOWED THE VEHICLE TO COOL OFF AND WAS FORCED TO ALLOW THE VEHICLE TO COOL DOWN SEVERAL TIMES BEFORE HE REACHED HIS RESIDENCE. THE VEHICLE WAS TAKEN TO A LOCAL RV MECHANIC WHO REPLACED THE ENTIRE BRAKE ASSEMBLY. HE STATED THAT THE REPAIRS WERE DONE IN 2006. HE RECEIVED A RECALL LETTER 09V110000, SERVICE BRAKES, HYDRAULIC FROM THE MANUFACTURER IN 2009. THE MANUFACTURER REFUSED TO REIMBURSE HIM BECAUSE OF THE DATE OF THE REPAIRS AND ADVISED HIM THAT THEY WERE NOT RESPONSIBLE FOR REPAIRS BEFORE NOVEMBER 2007. THE FAILURE MILEAGE WAS 8,960 AND THE CURRENT MILEAGE WAS 10,525.

TL* THE CONTACT OWNS A 2000 WORKHORSE W22. WHILE DRIVING AT APPROXIMATELY 40 MPH PRESSURE WAS APPLIED TO THE BRAKE PEDAL AND THE STEERING WHEEL BEGAN TO SHAKE. THE ANTI LOCK BRAKE SERVICES LIGHT ALSO BEGAN TO ILLUMINATE ON THE DASHBOARD. THE RV WAS TAKEN TO AN AUTHORIZED DEALER WHERE HE WAS INFORMED THE BRAKE ROTORS WERE WARPED AND THE BRAKE PADS WERE WORN DOWN. THE FAILURE AND CURRENT MILEAGES WERE 31,000. UPDATED 12/23/10*LJ THE CONSUMER STATED THE BRAKE PADS WERE REPLACED AT HIS EXPENSE. UPDATED 01/04/11*JB

TL* THE CONTACT OWNS A 2002 WORKHORSE W22 RV. THE CONTACT STATED HIS VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC). BOTH THE DEALER AND MANUFACTURER ADVISED THE PARTS NEEDED TO MAKE THE REPAIR WERE NOT AVAILABLE AND COULD NOT PROVIDE AN ESTIMATED TIME OF AVAILABILITY. THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THE RECALL LETTER WAS RECEIVED ONE YEAR AGO AND THE PARTS WERE STILL NOT AVAILABLE AFTER ONE YEAR. THE FAILURE MILEAGE WAS 14,179 AND THE CURRENT MILEAGE WAS 14,699.