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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

Owner complaints by model year

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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

What owners actually said

67 reports
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

30,840 miles · Oct 18, 2010
Service Brakes, Hydraulic

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 CO…

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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

NHTSA ODI #10361083

Mileage unknown · Oct 13, 2010
Service Brakes, Hydraulic

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 RECA…

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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

NHTSA ODI #10360870

60,000 miles · Sep 29, 2010
Service Brakes, HydraulicFire

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 …

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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.

NHTSA ODI #10358283

Mileage unknown · Sep 22, 2010
Engine And Engine Cooling

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 BECA…

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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

NHTSA ODI #10356489

8,960 miles · Sep 21, 2010
Service Brakes, HydraulicFire

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. …

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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.

NHTSA ODI #10356785

31,000 miles · Sep 15, 2010
Service Brakes, Hydraulic

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 WARP…

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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

NHTSA ODI #10355684

14,179 miles · Jul 14, 2010
Service Brakes, Hydraulic

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 AVAIL…

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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.

NHTSA ODI #10343196

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.