2003 Workhorse W22 complaints

VEHICLE HAD BRAKE FAILURE 3 TIMES IN 36K MILES. ADDITIONALLY, AXLE SEALS HAVE BEEN REPLACED 3 TIMES DUE TO EXCESSIVE HEAT FROM BRAKES. BRAKES AND SEALS HAVE ALL BEEN REPLACED 3 TIMES. SPOKE TO WORKHORSE NUMEROUS TIMES, WAS TOLD THERE IS NO MAINTENANCE TO DO ON BRAKES, JUST HAVE THEM INSPECTED TWICE A YEAR, AND HAVE THEM REPLACED IF STICKING, EVEN IF IT IS EVERY 10K MILES @ $2,000 PER REPAIR. *TR

RE: NHTSA ACTION NUMBER : EA07016 : --- WORKHORSE CUSTOM CHASSIS RECALL NUMBER 50401-C, NHTSA RECALL NOL 04V-084 FOR THE BOSCH ZOPS BRAKE PROBLEM WAS COMPLETED TO MY 2003 HOLIDAY RAMBLER VACATIONER, MODEL 36DBD MOTORHOME. - WHILE VACATIONING AND WITH JUST 2000 MILES +/- LATER MY RIGHT REAR BRAKES CALIPER LOCKED-UP, THE SMELL OF SMOKE CAME IN THE MOTORHOME AND THEN WHEN I WENT TO APPLY THE BRAKES, THEY WENT ALL THE WAY TO THE FLOOR. GOOD THING I WAS ABLE TO PULLED OVER ONTO THE SIDE OF THE HWY TO AVOID HAVING AN ACCIDENT. AFTER A WHILE WHEN THEY COOLED DOWN, I PUMPED THE BRAKES AND THEY SEEM TO BE WORKING OK. I WAS ABLE TO SLOWLY PROCEED TO MY CAMPGROUND. TOOK THE MOTORHOME TO AN AUTHORIZE WORKHORSE DEALER AND THEY REPLACE THE CALIPER ,PADS, SENSOR AND ROTOR. WORKHORSE DID COVERED THE EXPENSES FOR THIS REPAIRS. AT 11,000 MILES +/- LATER AFTER THE RECALL WORK WAS COMPLETED, THE RIGHT FRONT WHEEL SPEED SENSOR WENT BAD AND HAD TO BE REPLACED. NOW 18,000 MILES +/- LATER AFTER THE RECALL WAS COMPLETED, THE LEFT REAR BOSCH CALIPER HUNG-UP, OVERHEATED AND I HAD TO HAVE THE CALIPER, PADS, SENSOR AND ROTOR REPLACED. I THEN CONTACTED WORKHORSE CUSTOM CHASIS ABOUT REIMBURSING THE EXPENSES I INCURRED AND THEY DECLINED. - I'M VERY AFRAID THAT THE REMINDER OF THE ORIGINAL BOSCH CALIPERS COULD LOCK-UP, FAIL AND CAUSE ME TO HAVE AN ACCIDENT. ALL REPAIR WORK WAS DONE AT AN AUTHORIZE WORKHORSE CUSTOM CHASSIS SHOP. - PER THE VIN RECORDS THE LEFT WHEEL SPEED SENSOR WAS CHANGED OUT AT 42 MILES ON

2003 MONACO LAPALMA WITH 2003 WORKHORSE W22 CHASSIS. WITH DEFECTIVE FRONT ROTORS. CONSUMER STATES THAT THE RV BEGAN TO EXPERIENCE A VIBRATION. THE CONSUMER WAS INFORMED IT WAS BECAUSE THE ROTORS HAD EXCESSIVE HEAT WHICH CAUSED THEM TO CRACK. *KB UPDATED 03/16/10 *BF THE CONSUMER STATED THE HE EXPERIENCED WHAT WAS DESCRIBED IN THE RECALL THAT WAS ISSUED. *JB UPDATED 03/26/10.*JB WORKHORSE INFORMED THE CONSUMER HIS WARRANTY HAD EXPIRED PRIOR TO THE REPAIR FOR WHICH THE CONSUMER IS SEEKING REIMBURSEMENT. WORKHORSE FURTHER STATED THE RV WAS BUILT SEPTEMBER 3, 2002 WHICH MEANT HIS CHASSIS WAS NOT INCLUDED IN THE RECALL. UPDATED 04/20/10 THE CONSUMER ALSO STATED THE ABS SENSORS HAD TO BE REPLACED. UPDATED 07/28/10*JB

I HAVE THE SAME PROBLEM WITH MY 2003 WORKHORSE CUSTOM CHASSIS MOTORHOME AS INFORMATION IN NHTSA ACTION NUMBER PE07032. *TR

I HAVE A WORKHORSE CHASSIS WITH A BRAKE PROBLEM. SOUNDS LIKE ACTION # PEO732. I NOTICED DURING A TRIP TO FLORIDA IN APRIL THAT THE BRAKES SMELLED HOT AT THE REAR OF MOTORHOME DURING REFUELING. DURING MY TRIP TO SALT LAKE CITY AUGUST 1ST, 2007. MY BRAKE PEDAL WOULD GO TO THE FLOOR AND NOT COME BACK UP OR RELEASE THE BRAKES, I USED MY TOES TO BRING PEDAL BACK UP. IN UTAH I HAD A DIAGNOSTIC CENTER LOOK AT THE PROBLEM, THEY DETERMINED IT TO BE A BAD BOOSTER PUMP. THEY REPLACED THE PUMP AND PEDAL WOULD COME BACK UP AND RELEASE THE BRAKES, BUT STILL HAD A SOFT PEDAL. WHEN I GOT HOME (ARLINGTON TEXAS) BRAKES WERE NOT RELEASING PROPERLY. I CALLED WORKHORSE AND THEY TOLD ME WHERE TO TAKE THE MOTOR HOME FOR SERVICE. MOTOR HOME HAS BEEN IN THE SHOP FOR OVER 30 DAYS, THEY HAVE REPLACED THE POWER STEERING GEAR BOX, AND THE BOOSTER PUMP AGAIN. THEY TOLD ME THE MOTOR HOME WAS READY, NOTHING UNDER WARRANTY, I PAID THEM $4,558.85. WHEN I GOT IN THE MOTOR HOME THE BRAKE PEDAL WENT TO THE FLOOR, ALSO WOULD NOT START, WHICH WAS PROBABLY THE PEDAL NOT COMMING BACK UP AND LEAVING THE BRAKE LIGHTS ON. TECHNICIANS ARE BLEEDING THE BRAKES AND CHECKING IT OUT AGAIN. SEEMS WORKHORSE IS NO HELP IN RESOLVING THE PROBLEM. I AM NOW OUT THE $4,558.85 AT SOUTHWESET INTERNATIONAL TRUCKS HERE IN ARLINGTON TEXAS PLUS $1,089.25 FOR WORK ON BRAKES IN UTAH. AND I STILL DON'T HAVE A DRIVABLE MOTOR HOME. *TR

ABS, HYDRAULIC, CALIPER, ROTOR AND ALL BRAKE COMPONENTS. *TR

FRONT BRAKE FAILURE ON W22 RV CHASSIS, HAVE BEEN INFORMED THAT ALL 4 BRAKES NEED TO BE REPLACED AT 32,000 MILES. *TR

RIGHT FRONT BRAKE CALIPER LOCKED UP IN HEAVY TRAFFIC. HAD FIRE, WAS ABLE TO EXTINGUISH WITH ONBOARD EXTINGUISHER. MOTOR HOME WAS TOWED AND TAKED TO A WORKHORSE SERVICE CENTER. GEORGIA COMMERCIAL VEHICLES IN MARIETTA, GA. THEY REPLACED ONE CALIPER, ONE CRACKED ROTOR, RIGHT FRONT TURNED ROTOR ON LEFT FRONT. REPLACED BRAKE PADS FRONT AND REAR. TOTAL COST $937.51 CONTINUED ON OR TRIP BUT NOTICED ON GOING PROBLEMS WITH BRAKES BUT NO LOCKUP. UPON RETURN TO LEESBURG, FL. TOOK MH. TO NICHOLS DIESEL IN EUSTIS, FL . ANOTHER WORKHORSE SERVICE CENTER. THEY THE HAD TO REPLACE BOTH FRONT CALIPERS, TURNED THE NEW ROTOR ON THE RIGHT FRONT, RREPLACED THEROTOR ON LEFT FRONT, CRACKED. REPLACED BRAKE PADS ON FRONT.COST $1278.99. SENT LETTERS TO WORKHORSE BUT NO RESPONSE. CALLED WORKHORSE AND WAS TOLD THAT THE MOTORHOME WAS OUT OF WARRANTY AND NOT SUBJECT TO A RECALL EVER THOUGH IT HAD ONLY 28,554 MILES OF USE. THEY THIS WAS NORMAL. AFTER LOOKING ON THE INTERNET I DON'T THINK SO. WE WERE LUCKY THAT. *TR

ALL BRAKE CALIPERS WERE LUBED/INSPECTED ACCORDING TO MFR'S SPEC AT 26,174 MILES. ONE MONTH LATER, AT 26780 MILES, THE LF CALIPER WAS FOUND TO BE DRAGGING, CAUSING OVERHEATED BRAKE, & REQUIRED THE MOTORHOME TO BE TOWED. THE LF CALIPER PINS/BOOTS WERE REPLACED & ALL CALIPER PINS RE-LUBED/INSPECTED. APPROX ONE MONTH LATER AT 27610 MILES, THE RF CALIPER WAS DRAGGING, CAUSING OVERHEATING & STEERING PULLING RIGHT. AT THAT POINT I DIRECTED THAT THE LEFT & RIGHT FRONT CALIPERS BE REPLACED, AT CONSIDERABLE EXPENSE, BUT A NECESSARY SAFETY ITEM. MOTORHOME VEHICLE IS 2003 WINNEBAGO ADVENTURER 38G ON A 2003 WORKHORSE W-22 CHASSIS. ALL WEIGHTS ARE WITHIN SPECS (NOT OVERLOADED). *JB *UPDATED 12/12/2007 *BF UPDATED 12/12/07 *TR

BRAKE PEDAL FELL TO FLOOR WHEN ATTEMPTING A STOP WITHOUT ANY WARNING. ABS OR BRAKE LIGHT NEVER CAME ON. CARRIED TO SHOP AND FOUND REAR BRAKES HAD FAILED TO RELEASE, HEATING CALIPERS, PADS AND SENSORS. ALL HAD TO BE REPLACED. WORKHORSE REFUSED TO REFUND PAYMENT EVEN THOUGH HISTORY OF THESE VEHICLES PROVE THERE IS A MANUFACTURER DEFECT RELATING TO THE CALIPERS. THIS IS A DEFINITE SAFETY PROBLEM. UPON NOTIFICATION TO WORKHORSE THEY DID NOT EVEN ACKNOWLEDGE THE SAFETY HAZARD WITH THE NUMBER OF THIS SPECIFIC VEHICLE STILL IN SERVICE, IT IS ONLY A MATTER OF TIME BEFORE A SERIOUS ACCIDENT OCCURS. JH *TR THE CONSUMER STATED A RECALL WAS PERFORMED ON VEHICLES MADE IN 2001-2003 BUT THE CONSUMER'S VIN WAS NOT INCLUDED IN THE RECALL. THE CONSUMER STATED WANTED TO BE REIMBURSED FOR REPAIRS. UPDATED 09/11/07 *TR

RECALL CORNER ? JANUARY 2005 WORKHORSE CUSTOM CHASSIS HAS ANNOUNCED NHTSA RECALL 04V084000, WHICH AFFECTS CERTAIN WORKHORSE W SERIES GASOLINE-POWERED CHASSIS MADE BETWEEN AUGUST 10, 2000, AND JULY 29, 2002. THE POTENTIAL NUMBER OF CHASSIS AFFECTED IS 10,235. THESE CHASSIS WERE USED BY SEVERAL MOTORHOME MANUFACTURING COMPANIES. TO DETERMINE WHETHER YOUR COACH IS INCLUDED IN THIS RECALL, CHECK THE FOLLOWING VEHICLE IDENTIFICATION NUMBERS (VIN). ONLY THE LAST EIGHT DIGITS OF THE FULL 17-DIGIT VIN ARE GIVEN. ALL CHASSIS INVOLVED HAVE VINS THAT BEGIN WITH 5B4. CHASSIS MODEL YEAR 2001 ? 13325068 TO 13337849 CHASSIS MODEL YEAR 2002 ? 23336034 TO 23356051 CHASSIS MODEL YEAR 2003 ? 33354476 TO 33356806 ON SOME W20 AND W22 MOTORHOME CHASSIS BUILT BY WORKHORSE AND EQUIPPED WITH BOSCH ZERO OFFSET PIN SLIDE (ZOPS) BRAKE CALIPERS, THE CALIPER CAN HANG IN THE PARTIAL APPLY POSITION AND CAUSE THE BRAKE PADS TO DRAG ON THE ROTOR SURFACE. OVERHEATING MAY OCCUR, CAUSING DAMAGE TO THE BRAKE COMPONENTS AND AFFECTING BRAKING PERFORMANCE. THE PROBLEM ALSO COULD CAUSE THE BRAKE SYSTEM'S ANTI-LOCK FEATURES TO BE LOST IF THE HEAT DAMAGES THE ANTI-LOCK WHEEL SENSOR. *JB

DT: WHEN PUSHING ON THE BRAKES THEY WENT TO THE FLOORBOARD. THE VEHICLE HAD NOT BEEN TAKEN TO THE DEALERSHIP YET. THE MANUFACTURER STATED IT COULD BE TAKEN TO DEALERSHIP ON AUGUST 14, 2005. THE CONSUMER LOOKED AT THE VEHICLE AND FOUND FLUID LEAKING FROM UNDER THE TIRES. HE WAS NOT SURE WHAT KIND OF FLUID IT WAS. THIS HAPPENED ONCE ON JULY 26, 2005 AND IT HAPPENED AGAIN ON JULY 27, 2005. CONSUMER PULLED OVER AND PARKED THE VEHICLE. *AK THE ABS LIGHT ILLUMINATED AND THE VEHICLE WAS TAKEN TO THE AUTHORIZED REPAIR FACILITY AND THE BRAKES WERE REPAIRED. THE DEALER EXPLAINED THAT THE CALIPER SLIDE PIN HAD SEIZED CAUSING THE ROTORS TO HEAT UP. TEN MINUTES AFTER THE REPAIRS WERE MADE THE ABS LIGHT ILLUMINATED AGAIN. *NM

BRAKE PEDAL WENT TO FLOOR WHEN A SHORT OCCURRED IN THE ABS SYSTEM. THE BRAKES DIDN'T FUNCTION AT ALL UNTIL I PUMPED THEM A SECOND TIME. THE HAPPEN THREE TIMES BEFORE I COULD GET OFF THE HIGHWAY TO SAFE PLACE. *JB