2004 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 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.

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.

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.

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

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

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.

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.

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.

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

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

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

LEAKING GAS TANK AS PER NHTSA RECALL 10V348000. *TR

BOTH OF MY CATALYTIC CONVERTERS FAILED 2/16/11 ON MY 2004 W22 WORKHORSE CHASSIS WITH ONLY 30,000 MILES. REPLACEMENT COST $1,200.00. THERE WAS A RECALL REPLACING DEFECTIVE CATALYTIC CONVERTERS ON THE 2003 WORKHORSE CHASSIS. IS THIS THE CONTINUATION OF THE SAME PROBLEM OF DEFECTIVE CATALYTIC CONVERTERS? I'VE KEPT MY 8.1L TUNED AND SERVICED AS PER MANUFACTURE INSTRUCTIONS. *TR

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

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

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

THE ABOVE VEHICLE WAS PURCHASED ON 10/29/2010, WHILE CONDUCTING THE FIRST 30 DAY RIVING TEST, IT WAS NOTICED THAT THE INSTRUMENT CLUSTER WAS NOT FUNCTIONING PROPERLY, THE DISPLAY LIGHT WILL NOT COME ON AND THEREFORE HAD TO DRIVE IN THE EVENING WITHOUT THIS KNOWLEDGE. DURING THE DAILIGHT, WHEN I PLACED THE VEHICLE IN CRUISE CONTROL THE INSTRUMENT CLUSTER FAILED TO TELL ME SO. THERE ARE MANY OTHER FEATURES TO THIS INSTUMENT THAT I DO NOT KNOW IF THEY WORK OR NOT. UPON BRINGING THE VEHICLE BACK TO THE PURCHASING DEALER, I WAS TOLD THAT THE INSTRUMENT PANEL HAD BEEN PREVIOUSLY RECALLED BY THE MANUFACTURER AND THAT THE WORK HAD ALREADY BEEN COMPLETED ON APRIL 2010 AND THEREFORE IF I WANTED IT FIXED, I WOULD HAVE TO PAY APPROXIMATELY $600.00 TO GET IT FIXED. THIS VEHICLE WAS SOLD TO ME WHILE BEING UNSAFE TO DRIVE, HOW CAN THEY TELL ME THAT I WOULD HAVE TO PAY FOR A SAFETY REPAIR OF THIS MAGNITUDE WHEN IT DID NOT HAPPEN WHILE I OWNED THE VEHICLE. THE WORKHORSE RECALL NUMBER WAS BULLETIN NO. 50402-C. IT IS MY CONTENTION THAT THE DEALERSHIP SHOULD PAY FOR THIS VERY IMPORTANT PART OF THE SAFETY OF THIS VEHICLE.

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

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

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

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

TL- THE CONTACT OWNS A 2004 WINNEBAGO. THE CONTACT NOTICED THAT HIS NORCOLD REFRIGERATOR'S COOLING FLUID WAS LEAKING. THE REFRIGERATOR WAS INSPECTED BY THE CONTACTS PERSONAL MECHANIC WHO STATED THAT THE HIGH TEMPERATURE CENSOR NEEDED TO BE REPAIRED. THE REFRIGERATOR HAD BEEN REPAIRED; HOWEVER THE HIGH TEMPERATURE CENSOR NEEDS TO BE REPAIRED AGAIN. THE MANUFACTURER WAS CONTACTED, BUT THE CONTACT WAS NOT ABLE TO GET A LIVE OPERATOR. THE CURRENT AND FAILURE MILEAGE WAS APPROXIAMETLY 47,000. BW UPDATED 01/24/11 *BF

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.

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

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

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.

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.

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.

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

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

TL* THE CONTACT OWNS A 2004 NATIONAL SEA BREEZE LX RV. THE VEHICLE WAS EQUIPPED WITH A 2004 WORKHORSE CHASSIS W22. THE CONTACT WAS DRIVING APPROXIMATELY 45-55 MPH ON A MOUNTAIN WHEN HE SMELLED A STRONG BURNING ODOR NEAR THE BRAKES. THE VEHICLE WAS DRIVEN ONTO THE EMERGENCY LANE AND INSPECTED. THE CONTACT OBSERVED THAT THE FRONT PASSENGER SIDE WHEEL BEARING OIL CAP DISSOLVED WHICH CAUSED THE OIL LEAK. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER WHO CONFIRMED THAT THE FAILURE WAS CONTRIBUTED TO THE BRAKES OVER HEATING. THE FRONT PASSENGER SIDE SPINDLE BEARINGS AND FRONT WHEEL OIL SIGHT GLASS WERE REPLACED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER TWICE TO HAVE THE BRAKE CALIPERS REPLACED ON THE FRONT DRIVER SIDE. NHTSA RECALL CAMPAIGN ID NUMBER 09V110000 (SERVICE BRAKES, HYDRAULIC) WAS RELATED TO THE FAILURE; HOWEVER, THE PART WAS UNAVAILABLE. THE REPAIR PART HAS BEEN UNAVAILABLE FOR SEVEN MONTHS. THE DEALER RECENTLY ADVISED THE CONTACT THAT THE PART WOULD BE AVAILABLE IN OCTOBER OF 2010. THE FAILURE MILEAGE WAS 8,339.

2004 WORKHORSE RV. CONSUMER REQUESTS REIMBURSEMENT FOR REPAIRS DONE TO MOTOR HOME. CONSUMER STATES REPAIRS WERE REQUIRED DUE TO DAMAGE CAUSED BY BRAKE FAILURE AND OVERHEATING AS DESCRIBED AND COVERED IN THE TWO INTERIM SAFETY RECALL NOTICES. *TGW THE CONSUMER STATED THE BRAKES WOULD GRAB THEN SMOKE AND THE ABS LIGHT ILLUMINATED. *JB THE CONSUMER STATED THE BRAKES DRAGGED, THEN OVERHEATED AND THEN COMPLETE BRAKE FAILURE. UPDATED 09/15/10*JB

BRAKE DRAG, ABS LITE ON, BRAKE SMELL INSIDE MOTOR HOME,SHIMMY, BRAKE FADE, OIL SEALS LEAKING FRONT WHEELS, GREASE DRIPPING FROM KING PIN FITTING, UNABLE TO GET ABOVE 40 MPH. THIS OCCURS WITHIN 25 MILES OF TRAVEL. GARAGE CERTIFIED BY WORKHORSE TO REPAIR SAID IT WOULD NOT BE COVERED IN SAFETY RECALL BECAUSE IT WAS NOT BAD ENOUGH.

2004 PACE ARROW, 35-G RV MOTOR HOME WITH A W-22 WORKHORSE CHASSIS. CONSUMER REQUESTS REIMBURSEMENT FOR EXPENSES INCURRED FOR REPAIRS DUE TO RECALL 09V110000. *TGW THE CONSUMER STATED THE BRAKES LOCKED UP, THE ABS LIGHT ILLUMINATED AND THERE WAS A SMELL OF A BURNING FLUID. AN INSPECTION REVEALED A LEFT REAR FROZEN CALIPER, THE ABS SENSOR HAD MELTED, THE PADS WERE SCORED AND GLAZED, THE LEFT FRONT WHEEL SPEED SENSOR WAS DAMAGED, THE CALIPER SLIDES, PINS AND BUSHINGS WERE ALL DRY WHICH CAUSED A BIND WHEN BRAKING. THE LEFT AND RIGHT REAR ROTORS WERE RESURFACED, THE REAR CALIPERS AND PADS WERE REPLACED, THE SEAL, BOTH AXLES, SPINDLE SEALS, REAR ABS SENSORS AND LEFT FRONT ABS SENSOR WERE ALL REPLACED AND THE CALIPER SLIDES AND PINS WERE LUBED. A YEAR AND SEVERAL MONTHS LATER, THE BRAKES FAILED TO ENGAGE, THE ABS LIGHT ILLUMINATED AGAIN, AND THE BURNING FLUID ODOR HAD RETURNED. THE WHEELS WERE INSPECTED AND BRAKE FLUID HAD SPLATTERED OVER THE RIGHT FRONT WHEEL. THE RIGHT FRONT WHEEL WAS EXTREMELY HOT AND SMOKING. THE ABS LIGHT WAS NO LONGER ON. HOWEVER, WHEN THE CONSUMER ARRIVED TO THE NEAREST DEALER, THE BRAKES FAILED AGAIN AND THE ABS LIGHT WAS BACK ON. AN INSPECTION REVEALED THE FRONT CALIPERS WERE DRAGGING. THE FRONT CALIPERS, INNER OIL SEALS, WHEEL SPEED SENSORS AND THE RIGHT FRONT OUTER COVER WERE ALL REPLACED. *JB

2004 WORKHORSE W22 CHASSIS. 2004 MOTORHOME CLASS A/PACE ARROW CALIPER STUCK. *BF THE CONSUMER STATED THERE WAS A BURNING SMELL COMING FROM THE LEFT FRONT WHEEL AND THE ABS LIGHT WAS ON. HE TOOK THE VEHICLE TO AN RV DEALER WHERE IT WAS DISCOVERED THE CALIPER WAS STUCK ON THE LEFT FRONT WHEEL. IN EARLY NOVEMBER 2007 HE ENCOUNTERED A SIMILAR PROBLEM INVOLVING THE REAR WHEELS AND AGAIN THE SAME SITUATION WAS FOUND AND FIXED. THE CONSUMER ATTACHED INVOICES AND BELIEVED THE PROBLEMS HE EXPERIENCED FELL UNDER THE RECALL THAT WAS ISSUED. *JB

2004 WORKHORSE W22 CHASSIS. THE CONSUMER RECEIVED A RECALL NOTICE FROM WORKHORSE WHICH STATED THE CLIP THAT RETAINS THE ENGINES FUEL RAIL PULSE DAMPER MAY FRACTURE LEADING TO A FUEL LEAK. *DT THE CONSUMER WAS HAVING DIFFICULTY CONTACTING SOMEONE REGARDING THE RECALL NOTICE HE RECEIVED. THE CONSUMER ALSO COMPLAINED ABOUT LOSS OF BRAKES ON THE RV. WHEN THE CONSUMER ATTEMPTED TO APPLY THE BRAKE TO STOP, THE PEDAL WENT TO THE FLOOR. HE IMMEDIATELY PULLED THE SAFETY BRAKE AND PUMPED WHAT LITTLE BRAKE PEDAL HE HAD. THE NEXT DAY, THE CONSUMER DROVE TO THE DEALER WHERE HE WAS INFORMED A RECALL HAD BEEN ISSUED REGARDING THE PROBLEM HE EXPERIENCED. *JB

BRAKE FAILURE WHEN DRIVING THROUGH TOWN STOPPING FOR A LIGHT. *TR

TL*THE CONTACT OWNS A 2004 FLEETWOOD PACE ARROW RV. THE VEHICLE WAS BUILT ON A 2004 WORKHORSE CHASSIS W22. WHILE DRIVING APPROXIMATELY 60 MPH ON NORMAL ROAD CONDITIONS A BURNING SMELL WAS COMING FROM THE BRAKE SYSTEM. THE DRIVER PULLED OVER TO THE SIDE OF THE ROAD. THE VEHICLE RESUMED OPERATION WITH THE ANTI-BRAKE SYSTEM (ABS) WARNING LIGHT INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE WARNING INDICATOR REMAINED ILLUMINATED UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION. THE ANTI-LOCK BRAKE SENSOR MELTED WHICH WAS REPLACED. NHTSA CAMPAIGN ID NUMBER 09V110000, SERVICE BRAKES, HYDRAULIC IS RELATED TO THE FAILURE; HOWEVER, THE RECALL REMEDY PART WAS UNAVAILABLE. THERE WERE CONCERNS OF THE SAFETY RISKS INVOLVED AND THE UNCERTAINTY OF THE AVAILABILITY OF THE PART. THE FAILURE MILEAGE WAS 43,500. UPDATED 02/02/10 *BF UPDATED 02/02/10.*JB UPDATED 02/19/10. *LJ UPDATED 02/19/10.*JB UPDATED 07/12/10*JB

WORKHORSE SAFETY RECALL 50901-C EVENT. FRONT DRIVER WHEEL CHATTERED DUE TO CALIPER STICKING IN CLOSED POSITION ONTO ROTOR, RESULTING IN OVERHEATING THAT CAUSED FLUID TO OVERHEATED AND LEAK OUT OF WHEEL HUB. CALIPER REQUIRED TO BE REPLACED. THE CONSEQUENCES THAT OCCURRED WAS THAT THE VEHICLE COULD NOT BE DRIVEN BECAUSE BRAKES WOULD NOT WORK PROPERLY. SOLUTION IS FOR WORKHORSE TO REPLACE CALIPERS WITH ONES THAT DO NOT STICK. ONES CURRENT ON VEHICLE ARE THE TYPE THAT ARE SUBJECT TO THE FAILURE MODE DESCRIBED ABOVE. *TR

TL* THE CONTACT OWNS A 2004 WORK HORSE W22 CHASSIS MODEL TIPPING ALLEGRO. DURING BRAKE APPLICATION AT 35 MPH THE PEDAL WENT COMPLETELY TO THE FLOOR. HE ENGAGED THE PARKING BRAKE TO STOP THE VEHICLE. A MECHANIC COULD NOT IDENTIFY THE CAUSE OF THE FAILURE. THE MANUFACTURER STATED A LETTER WAS SENT TO THE OWNERS ADVISING THAT THE CALIPERS COULD CAUSE THE BREAKS TO OVER HEAT AND FAIL. HOWEVER HE NEVER RECEIVED THE LETTER. HE TOOK THE RV TO THE DEALER. THE DEALER STATED THEY WILL NEED TO DUPLICATE THE PROBLEM TO BE ABLE MAKE ANY NECESSARY REPAIRS. HE ADDED THAT IF ANY PARTS WERE REPLACED IT WOULD BE REPLACED WITH THE SAME MATERIAL AND IT WILL NOT BE A PERMANENT REMEDY. THE CURRENT AND THE FAILURE MILEAGES WERE 36,000.

WORKHORSE CHASSIS W22 2004 MILEAGE 17500 MILES BRAKES OVERHEATED, PADS MELTED TO ROTORS ABS SENSOR ON RIGHT WHEEL MELTED. HAD TO REPLACE ROTORS, PADS AND SENSOR. WORKHORSE REFUSE RESPONSIBILITY BECAUSE CALIPER MALFUNCTION DID NOT DESTROY CALIPER ENOUGH EVEN THOUGH THEY ARE AWARE OF PROBLEMS. PARTS WEE LEFT WITH REPAIR SHOP WHO HAS PICTURES. *TR

CONSUMER WANTS TO BE REIMBURSED FOR THE REPAIR WORK DONE ON THEIR 2004 FLEETWOOD BOUNDER FOR SAFETY RECALL 50901-C. *NJ WHILE DRIVING, THERE WAS AN ODOR OF HOT BRAKES. THE CONSUMER STOPPED AT A WEIGH STATION AND CHECKED THE BRAKES, BUT THEY DIDN'T SEEM VERY HOT. AFTER ABOUT 6 OR 7 MILES, THE ODOR BECAME STRONGER. THE CONSUMER PULLED OVER AND WHEN CHECKING THE BRAKES, THE ANTI-LOCK SENSOR ON THE DRIVERS SIDE BLEW OUT. THE NEXT DAY, THE RV WAS TAKEN TO A SHOP WHERE IT WAS DISCOVERED THE CALIPERS HAD FROZE AND NEEDED TO BE REPLACED.(WORKHORSE 2004 W22 CHASSIS) *JB

TL*THE CONTACT OWNS A 2004 TIFFIN ALLEGRO BAY MOTOR HOME WITH A W22 WORKHORSE CHASSIS. THE CONTACT STATED THAT DURING APPLICATION THERE IS ABNORMAL HEAT GENERATION AT THE WHEEL END WHICH CAUSES BRAKE DRAG AND STICKING. THIS CAN EVENTUALLY LEAD TO SOFT PEDAL CONDITIONS DUE TO BRAKE FLUID BOIL, AND POSSIBLE EXTENDED STOPPING DISTANCE INCREASING THE RISK OF A CRASH. HE CONTACTED THE DEALER IN REFERENCE TO RECALL# 09V110000 (SERVICE BRAKES, HYDRAULIC), BUT BECAUSE THE PARTS WERE UNAVAILABLE THE FAILURES HAVE NOT BEEN PROPERLY REMEDIED.. THE FAILURE MILEAGE WAS 31,254. THE CONSUMER STATED HE HAD TO APPLY THE BRAKES WHEN A VEHICLE SUDDENLY PULLED IN FRONT OF HIM. WHEN HE STARTED TO ACCELERATE, HE NOTICED THE RV WASN'T ACCELERATING AND HE IMMEDIATELY PULLED OVER. HE DISCOVERED THE REAR WHEELS WERE EXTREMELY HOT TO TOUCH AND BRAKE FLUID WAS BOILING OUT OF THE RESERVOIR. THE RV WAS INSPECTED AND IT WAS DISCOVERED THAT THE RIGHT REAR CALIPER HAD FROZEN TO THE ROTOR. WORKHORSE AUTHORIZED THE REPLACEMENT OF THE BRAKE SHOES AND CALIPER. UPDATED 09/29/09.*JB UPDATED 01/13/10. *JB

2004 WORKHORSE HAD A PROBLEM WITH THE BRAKES LOCKING UP. *NJ THE CONSUMER TOOK THE RV TO A REPAIR SHOP AND WAS INFORMED TWO OF THE BRAKE CYLINDERS HAD LOCKED UP. WORKHORSE DENIED THE CONSUMERS CLAIM STATING THE DAMAGE WAS NORMAL WEAR. THE MECHANIC, HOWEVER STATED THERE WAS A RECALL REGARDING THIS VERY ISSUE. *JB

TL*THE CONTACT OWNS A 2004 ITASCA SUNOVA ON A WORKHORSE CHASSIS. WHILE DRIVING 35 MPH, THE STEERING TIGHTENED UP. WHEN THE CONTACT PULLED INTO THE DRIVEWAY, HE NOTICED SMOKE COMING FROM THE REAR PASSENGER SIDE CALIPER. HE ALLOWED THE RV TO COOL DOWN FOR A FEW DAYS BEFORE DRIVING IT TO THE DEALER. THE DEALER STATED THAT THE REAR PASSENGER SIDE CALIPER WAS DEFECTIVE, WHICH CAUSED THE BRAKES TO DRAG AND OVERHEAT. THE MANUFACTURER STATED THAT THEY WILL PROVIDE THE CALIPER AND HE WILL PAY FOR THE LABOR. THE FAILURE MILEAGE WAS 31,540 AND CURRENT MILEAGE WAS 31,544. UPDATED 8/28/09 *CN UPDATED 09/04/09.*JB

TL*THE CONTACT OWNS A 2004 FOUR WINDS INFINITY 35F RV. THE VEHICLE WAS EQUIPPED WITH WORKHORSE CUSTOM CHASSIS BRAKES. WHILE DRIVING APPROXIMATELY 10 MPH, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT EXPERIENCED EXTREME DIFFICULTY SLOWING DOWN THE VEHICLE. SUDDENLY, THE ABS WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE PARKING BRAKE WAS ENGAGED AND THE VEHICLE PROCEEDED TO A COMPLETE STOP. THE WARNING INDICATOR REMAINED ILLUMINATED UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE RESUMED OPERATION AFTER BEING PARKED FOR TWO CONSECUTIVE DAYS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION, BUT THEY COULD NOT DETERMINE THE CAUSE OF THE FAILURE. IN ADDITION, THE ROTORS WERE CRACKED. CURRENTLY, THE VEHICLE IS BEING REPAIRED AT THE COST OF $2,500. THE AUTHORIZED DEALER NOTIFIED THE MANUFACTURER CONCERNING THE RECALL REMEDY REPAIR; HOWEVER, THE MANUFACTURER HAS REFUSED TO REPAIR THE VEHICLE BECAUSE THE CALIPER FAILURE HAS NOT YET BEEN CONFIRMED. THE FAILURE AND CURRENT MILEAGES WERE 34,060. UPDATED 09/01/09. *LJ THE SEALS AND CALIPERS WERE REPLACED. THE LEFT FRONT WHEEL WAS DRAGGING AND OVERHEATED. UPDATED 09/09/09*JB

SAFETY RECALL 50901-C ON 2005 ALLEGRO MOTOR HOME. *NJ THE CONSUMER HAS A 2004 WORKHORSE W22. IN DECEMBER 2008 THE CONSUMER BEGAN TO EXPERIENCE A BRAKE DRAGGING SOUND, SO HE TOOK THE MOTORHOME TO THE DEALER FOR AN INSPECTION. THE SHOP DETERMINED THAT THE BRAKE LININGS WERE BAD, EVEN THE MOTORHOME HAD ONLY 32,000 MILES. THE CALIPERS CONTAINED A LITTLE RUST, AND THEY WERE CLEANED AND RE-INSTALLED. ON JANUARY 6, 2009 THE CONSUMER SMELLED A BURNING SMELL. EXAMINATION OF THE TIRES REVEALED AN OVERHEATED REAR TIRE. THE PROBLEM WAS WITH THE CALIPER, WHICH WAS REPLACED. ON MARCH 29, 2009 THE MOTORHOME BEGAN TO PULL TO THE RIGHT AND THERE WAS A SMELL OF SMOKE. THE CONSUMER PULLED OVER AND DISCOVERED THE RIGHT FRONT TIRE WAS SMOKING AND RED HOT FLUID WAS LEAKING FROM THE WHEEL. THE CONSUMER WENT TO A LOCAL SHOP AND WAS TOLD THE PROBLEM WAS THE CALIPERS. *JB

BRAKE FAILURE ON FLEETWOOD 2004 PACE ARROW MOTOR HOME. *TR THE CONSUMER IS SEEKING REIMBURSEMENT FOR THE REPLACEMENT OF THE REAR CALIPERS. 2004 WORKHORSE W22. UPDATED 10/07/09

AFTER TWO HOUR TRIP IN AN 04 WINNABAGO W22 CHASIS WE DISCOVERED THE BRAKES WERE DRAGGING AND SUBSEQUENTLY BOILED THE BRAKE FLUID ; BRAKE PEDAL TO THE FLOOR! *TR

TL*THE CONTACT OWNS A 2004 GULF STREAM SUN VOYAGER RV. THE VEHICLE HAS A WORKHORSE W22 CHASSIS. IN JULY OF 2008, THE FRONT DRIVER'S SIDE CALIPER CAUGHT FIRE. THE CALIPER WAS REPLACED. ON MAY 22, 2009, THE CONTACT FELT THE VEHICLE PULLING TO ONE SIDE WHILE DRIVING 65 MPH. SHE PULLED THE VEHICLE OVER AND NOTICED THAT THE REAR PASSENGER SIDE CALIPER WAS OVERHEATING. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY REPLACED THE CALIPER. THE MANUFACTURER FILED A REPORT AND REQUESTED DOCUMENTATION IN ORDER TO CONSIDER PROVIDING REIMBURSEMENT. THE FAILURE MILEAGE WAS 12,800 AND CURRENT MILEAGE WAS 13,889.

WORKHORSE MOTOR HOME 2004 REAR LEFT BRAKE CALIPER FAILURE. *TR