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2002 Workhorse W22

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

43 reports with mileage · 24 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 62 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 2 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports6 fire reports0 injury reports

Service Brakes, Hydraulic complaints

62 reports
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Mileage unknown · Sep 30, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 W22 WORKHORSE CHASSIS TRAILER. THERE IS AN ABNORMAL HEAT GENERATION AT THE WHEEL END WHICH CAUSED THE BRAKES TO DRAG. THE MANUFACTURER WAS NOTIFIED IN REFERENCE TO RECALL # 09V110000 (SERVICE BRAKES, HYDRAULIC). HE WAS ADVISED THAT A REMEDY HAS NOT BEEN DEVELOPED; THEREFORE, NO REPAIRS COULD BE MADE. T…

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TL*THE CONTACT OWNS A 2002 W22 WORKHORSE CHASSIS TRAILER. THERE IS AN ABNORMAL HEAT GENERATION AT THE WHEEL END WHICH CAUSED THE BRAKES TO DRAG. THE MANUFACTURER WAS NOTIFIED IN REFERENCE TO RECALL # 09V110000 (SERVICE BRAKES, HYDRAULIC). HE WAS ADVISED THAT A REMEDY HAS NOT BEEN DEVELOPED; THEREFORE, NO REPAIRS COULD BE MADE. THE FAILURE AND CURRENT MILEAGES WERE NOT APPLICABLE.

NHTSA ODI #10285847

Mileage unknown · Sep 23, 2009
Exterior LightingService Brakes, Hydraulic

LETTER FROM CONSUMER RE RECALL FOR BRAKE PROBLEMS WITH WORKHORSE CHASSIS. *NJ WHILE ON A TRIP, THE BRAKES OVERHEATED. THE RV WAS TAKEN TO THE DEALER AND IT WAS FOUND THAT THE ENTIRE BRAKING SYSTEM WAS DEFECTIVE. THE CONSUMER WAS INFORMED THE PARTS WOULD NOT BE AVAILABLE UNTIL NOVEMBER EVEN THOUGH THE ISSUE WAS A RECALL. THE …

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LETTER FROM CONSUMER RE RECALL FOR BRAKE PROBLEMS WITH WORKHORSE CHASSIS. *NJ WHILE ON A TRIP, THE BRAKES OVERHEATED. THE RV WAS TAKEN TO THE DEALER AND IT WAS FOUND THAT THE ENTIRE BRAKING SYSTEM WAS DEFECTIVE. THE CONSUMER WAS INFORMED THE PARTS WOULD NOT BE AVAILABLE UNTIL NOVEMBER EVEN THOUGH THE ISSUE WAS A RECALL. THE BRAKES LIGHTS REMAINED ON AFTER THE PEDAL WAS RELEASE. THE MECHANIC FOUND AN INTERNAL SHORT IN THE MULTI-FUNCTION SWITCH. THE HAZARD LIGHTS WERE NOT WORKING. *JB

NHTSA ODI #10285393

15,000 miles · Sep 23, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 HOLIDAY RAMBLER VACATIONER. THE CONTACT STATED HEAT BUILDS UP IN THE BRAKE SYSTEM. THE RV WAS TAKEN TO THE DEALER AND THE CALIPERS AND ROTORS WERE REPLACED. IMMEDIATELY AFTER THE REPAIR HE NOTICED THAT THE TRANSMISSION WOULD NOT CHANGE GEARS AND THE SPEEDOMETER WAS INOPERATIVE. HE NOTIFIED THE DEALER …

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TL*THE CONTACT OWNS A 2002 HOLIDAY RAMBLER VACATIONER. THE CONTACT STATED HEAT BUILDS UP IN THE BRAKE SYSTEM. THE RV WAS TAKEN TO THE DEALER AND THE CALIPERS AND ROTORS WERE REPLACED. IMMEDIATELY AFTER THE REPAIR HE NOTICED THAT THE TRANSMISSION WOULD NOT CHANGE GEARS AND THE SPEEDOMETER WAS INOPERATIVE. HE NOTIFIED THE DEALER BUT WAS NOT PROVIDED WITH ANY ASSISTANCE. THE FAILURE AND CURRENT MILEAGES WERE 15,000. CONSUMER IS UPDATING INFORMATION. 10/15/09 *NJ THE CONSUMER ALSO STATED THE ABS LIGHT ILLUMINATED. THE CONSUMER STATED AFTER ALL THE PROBLEMS HE EXPERIENCED, HE FINALLY RECEIVED A RECALL FROM WORKHORSE. THE CONSUMER WAS INFORMED DUE TO THE BRAKES OVERHEATING, THEY PROBABLY CAUSED DAMAGE TO THE TRANSMISSION. THE CALIPERS WERE BAD AND THE ABS FUSES WERE HANGING DOWN AND BURNED UP. UPDATED 10/16/09 UPDATED 10/20/09 *CN UPDATED 10/23/09.*JB

NHTSA ODI #10285045

Mileage unknown · Sep 14, 2009
Service Brakes, Hydraulic

2002 WINNEBAGO ADVENTURER 35-U HAD A BRAKE PROBLEM. CONSUMER WANTS TO BE REIMBURSED FOR THE REPAIRS (SAFETY RECALL 50901-C). *NJ THE RIGHT FRONT CALIPER LOCKED UP AND THE LEFT REAR CALIPER WAS DRAGGING. 2002 WORKHORSE W22 CHASSIS. UPDATED 09/14/09. *JB THE CONSUMER IS SEEKING REIMBURSEMENT FOR THE REPAIRS MADE TO THE BRAKE…

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2002 WINNEBAGO ADVENTURER 35-U HAD A BRAKE PROBLEM. CONSUMER WANTS TO BE REIMBURSED FOR THE REPAIRS (SAFETY RECALL 50901-C). *NJ THE RIGHT FRONT CALIPER LOCKED UP AND THE LEFT REAR CALIPER WAS DRAGGING. 2002 WORKHORSE W22 CHASSIS. UPDATED 09/14/09. *JB THE CONSUMER IS SEEKING REIMBURSEMENT FOR THE REPAIRS MADE TO THE BRAKES. UPDATED 08/04/10.*JB

NHTSA ODI #10284291

Mileage unknown · Aug 26, 2009
Service Brakes, Hydraulic

CONSUMER IS SEEKING REIMBURSEMENT FOR REPAIRS AFTER RECEIVING SAFETY RECALL 50901-C FOR WORKHORSE RV. *NJ PRIOR TO RECEIVING THE RECALL, THE FRONT BRAKES OVERHEATED. THE ROTORS, CALIPERS, INNER SEALS, RIGHT REAR SPEED SENSOR, HUB SEALS AND OUTER GASKET WERE REPLACED. *JB

NHTSA ODI #10282148

16,500 miles · Jul 17, 2009
Service Brakes, HydraulicFire

DRIVER SIDE REAR BRAKE FIRE ON 2002 WORKHORSE MOTOR HOME CHASIS. FIRE WAS NOTED WHEN STOPPING AT CAMPGROUND ENTRANCE AFTER TRAVELING ABOUT 5 MILES ON LEVEL GROUND AT 25 MILES PER HOUR FROM HIGHWAY ON SIDE ROAD. IMMEDIATELY HOSED DOWN BRAKE ASSEMBLY. MOTORHOME WAS ALLOWED TO SET FOR 3 DAYS. DROVE MOTORHOME AFTERWARDS WITH NO …

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DRIVER SIDE REAR BRAKE FIRE ON 2002 WORKHORSE MOTOR HOME CHASIS. FIRE WAS NOTED WHEN STOPPING AT CAMPGROUND ENTRANCE AFTER TRAVELING ABOUT 5 MILES ON LEVEL GROUND AT 25 MILES PER HOUR FROM HIGHWAY ON SIDE ROAD. IMMEDIATELY HOSED DOWN BRAKE ASSEMBLY. MOTORHOME WAS ALLOWED TO SET FOR 3 DAYS. DROVE MOTORHOME AFTERWARDS WITH NO PROBLEM. CONTACTED MANUFACTURER WORKHORSE, THEY SAID THE BRAKE CALIPER WAS STUCK AND THAT IT SHOULD NOT HAPPEN AGAIN AND THE VEHICLE IS OKAY TO DRIVE. I AM VERY CONCERNED ABOUT DRIVING THE VEHICLE. *TR

NHTSA ODI #10277112

32,870 miles · Jul 8, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 WORKHORSE W22 MOTOR HOME. THE CONTACT STATED THAT THE BRAKES FAILED DURING STOP-AND-GO TRAFFIC. HE ALSO STATED THAT THE BRAKES WERE DRAGGING. THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE MANUFACTURER STATED THAT THEY WOULD ASSIST WITH THE REPAIRS AND THAT THE VEHICLE WAS INCLUDE…

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TL*THE CONTACT OWNS A 2002 WORKHORSE W22 MOTOR HOME. THE CONTACT STATED THAT THE BRAKES FAILED DURING STOP-AND-GO TRAFFIC. HE ALSO STATED THAT THE BRAKES WERE DRAGGING. THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE MANUFACTURER STATED THAT THEY WOULD ASSIST WITH THE REPAIRS AND THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN ID NUMBER 09V11000. THE DEALER STATED THAT THEY NEEDED APPROVAL DIRECTLY FROM THE MANUFACTURER BEFORE MAKING ANY REPAIRS. THE MANUFACTURER COULD NOT BE REACHED. THE MILEAGES WERE UNKNOWN. UPDATED 8/10/09 *CN UPDATED 08/13/09.*JB

NHTSA ODI #10276112

Mileage unknown · Jun 15, 2009
Service Brakes, Hydraulic

WORKHORSE SAFETY RECALL 50901C. *NJ THE CONSUMER STATED THE BRAKES WERE HOLDING. THE CONSUMER TOOK THE RV TO A MECHANIC AND WAS TOLD THE ABS SENSORS HAD MELTED AND WOULD HAVE TO BE ORDERED. THE CONSUMER WENT BACK TO HAVE THE SENSORS INSTALLED, BUT WAS TOLD A THIRD SENSOR WAS BAD. THE BRAKES NEEDED A COMPLETE REBUILD DUE TO TH…

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WORKHORSE SAFETY RECALL 50901C. *NJ THE CONSUMER STATED THE BRAKES WERE HOLDING. THE CONSUMER TOOK THE RV TO A MECHANIC AND WAS TOLD THE ABS SENSORS HAD MELTED AND WOULD HAVE TO BE ORDERED. THE CONSUMER WENT BACK TO HAVE THE SENSORS INSTALLED, BUT WAS TOLD A THIRD SENSOR WAS BAD. THE BRAKES NEEDED A COMPLETE REBUILD DUE TO THE DAMAGE CAUSED BY HEAT.*JB

NHTSA ODI #10274468

7,210 miles · Jun 15, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2003 FOREST RIVER WINDSONG WITH A 2002 WORKHORSE W22 CHASSIS. WHILE DRIVING 55 MPH, THE FRONT END OF THE VEHICLE VIBRATED CONSTANTLY. THE CONTACT INSPECTED THE VEHICLE AND NOTICED AN ODOROUS SMOKE COMING FROM UNDERNEATH. HE POURED WATER ON THE BRAKE CALIPERS TO COOL THEM DOWN IN ORDER TO RETURN TO HIS RE…

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TL*THE CONTACT OWNS A 2003 FOREST RIVER WINDSONG WITH A 2002 WORKHORSE W22 CHASSIS. WHILE DRIVING 55 MPH, THE FRONT END OF THE VEHICLE VIBRATED CONSTANTLY. THE CONTACT INSPECTED THE VEHICLE AND NOTICED AN ODOROUS SMOKE COMING FROM UNDERNEATH. HE POURED WATER ON THE BRAKE CALIPERS TO COOL THEM DOWN IN ORDER TO RETURN TO HIS RESIDENCE. HE STATED THAT THE BRAKES SEEMED TO HAVE LOCKED UP, WHICH CAUSED THE VIBRATION. THE VEHICLE HAS NOT BEEN TAKEN TO THE DEALER AND THE MANUFACTURER HAS NOT BEEN NOTIFIED. PRIOR TO THE FAILURE, THE CONTACT RECEIVED AN INTERIM NOTICE THAT ALERTED HIM TO A POSSIBLE DEFECT WITH THE BRAKES. THE CURRENT AND FAILURE MILEAGES WERE 7,210. UPDATED 06/24/09. *LJ UPDATED 06/26/09.*JB

NHTSA ODI #10273788

20,000 miles · May 26, 2009
Electrical SystemService Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 WINNEBAGO ADVENTURER RV, MODEL 35U. THE CONTACT RECEIVED A RECALL NOTICE REGARDING THE BRAKING SYSTEM ON THE VEHICLE. IN OCTOBER OF 2008, THE BRAKES FAILED AND NEARLY CAUSED A CRASH. THE CONTACT CALLED THE DEALER AND A LAWYER AND WAS ADVISED TO FILE A COMPLAINT WITH THE ATTORNEY GENERAL IN PENNSYLVA…

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TL*THE CONTACT OWNS A 2002 WINNEBAGO ADVENTURER RV, MODEL 35U. THE CONTACT RECEIVED A RECALL NOTICE REGARDING THE BRAKING SYSTEM ON THE VEHICLE. IN OCTOBER OF 2008, THE BRAKES FAILED AND NEARLY CAUSED A CRASH. THE CONTACT CALLED THE DEALER AND A LAWYER AND WAS ADVISED TO FILE A COMPLAINT WITH THE ATTORNEY GENERAL IN PENNSYLVANIA. THE ATTORNEY GENERAL REFERRED THE CONTACT TO THE ATTORNEY GENERAL IN OHIO. THE DEALER REFUSED TO REPAIR THE VEHICLE. THE VEHICLE HAS BEEN PARKED AT A STORAGE FACILITY SINCE OCTOBER 10, 2008 AND HAD TO BE TOWED. THE COST TO REPAIR THE VEHICLE WAS ESTIMATED BETWEEN $3,000 AND $5,000. PRIOR TO THE FAILURE, THE DEALER CHARGED $795 FOR A SYSTEM CHECK. WHILE DRIVING APPROXIMATELY 40 MPH DOWN A HILL, THE VEHICLE FAILED AND WAS TOWED AWAY. THE CONTACT CALLED THE MANUFACTURER, BUT THERE WAS NO ANSWER. THE DEALER WAS NOTIFIED OF THE NEAR CRASH AND HUNG UP THE PHONE ON THE CONTACT. THE NHTSA CAMPAIGN ID NUMBER WAS UNKNOWN. THE CURRENT MILEAGE WAS 20,000. THE CONSUMER ALSO HAD ELECTRICAL PROBLEMS WITH THE RV. UPDATED 06/16/09.*JB

NHTSA ODI #10269910

Official recalls

2

09V110000 · Service Brakes, Hydraulic

Apr 3, 2009

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.

Consequence & remedy

Consequence: 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.

04V084000 · Service Brakes, Hydraulic

Feb 18, 2004

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

Consequence & remedy

Consequence: 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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA07016 · 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.