NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
62 reportsClear category filter21,000 miles · Mar 23, 2023
Service Brakes, Hydraulic
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 wa…
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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.
NHTSA ODI #11513439
Mileage unknown · Mar 25, 2011
Service Brakes, Hydraulic
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
NHTSA ODI #10393224
14,000 miles · Mar 25, 2011
Service Brakes, Hydraulic
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
NHTSA ODI #10392929
Mileage unknown · Jan 21, 2011
Service Brakes, Hydraulic
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 CA…
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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
NHTSA ODI #10377848
Mileage unknown · Jan 20, 2011
Service Brakes, Hydraulic
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
NHTSA ODI #10376211
Mileage unknown · Dec 17, 2010
Service Brakes, Hydraulic
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 …
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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
NHTSA ODI #10370251
40,126 miles · Dec 3, 2010
Service Brakes, Hydraulic
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…
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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
NHTSA ODI #10369079
88,000 miles · Nov 26, 2010
Service Brakes, Hydraulic
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 VE…
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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.
NHTSA ODI #10367873
Mileage unknown · Nov 17, 2010
Service Brakes, Hydraulic
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
NHTSA ODI #10366290
40,000 miles · Oct 19, 2010
Service Brakes, Hydraulic
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 …
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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
NHTSA ODI #10361241
NHTSA investigations
2EA07016 · Overheating Disc Brake Caliper
Opened Nov 16, 2007 · Closed Aug 19, 2009
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Additional source detail variants (7)
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
Service Brakes, Hydraulic
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.
EA03003 · Overheating Front And Rear Brakes
Opened Apr 9, 2003 · Closed Mar 3, 2004
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:foundation Components
THIS INVESTIGATION WAS DERIVED FROM INFORMATION GATHERED DURING PE02-046, BOSCH DISC BRAKE CALIPERS.THIS INVESTIGATION FOCUSED ON THE VEHICLE MANUFACTURER, NEWMAR.SUBJECT VEHICLES WERE THOSE BUILT WITH A HYDRAULIC BRAKE SYSTEM INCORPORATING THE BOSCH ZERO OFFSET PIN SLIDE (ZOPS) CALIPERS.ODI'SCONCERN WASEXCESSIVE WHEEL END HEAT, POSSIBLY RESULTING IN A WHEEL END FIRE.DURING THE INVESTIGATION, ODI DISCOVERED TWO SPECIFIC NEWMAR VEHICLE MODELS, THOSE BUILT ON NEWMAR CHASSIS AND THOSE BUILT ON A WORKHORSE CHASSIS. AS A RESULT OF THE AGENY'S INVESTIGATION INTO THIS MATTER, ALL NEWMAROWNERS WILL BE NOTIFIED (04V-019) AND THE REMEDY WILL BE APPLIED TO THEIR VEHICLES. SOME NEWMAR VEHICLES (1,795) BUILT ON THE WORKHORSE CHASSIS ARE BEING RECALLED BY WORKHORSE (04V-084).THIS INVESTIGATION IS CLOSED.FURTHER DETAILS ARE PROVIDED ON PAGES 2, 3, AND 4.COPIES OF BOTH SAFETY RECALLS ARE ATTACHED.
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