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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
Mileage unknown · Jun 16, 2010
Service Brakes, Hydraulic

2002 WORKHORSE W22 CUSTOM CHASSIS OWNER. CONSUMER EXPRESSES DISCONTENT REGARDING WORKHORSE ONLY TAKING PARTIAL FINANCIAL RESPONSIBILITY FOR FAULTY BRAKE SYSTEM REPAIRS *TGW THE CONSUMER STATED THE ABS ILLUMINATED AND THERE WAS A VIBRATION DURING BRAKING. THE RV WAS TAKEN TO A REPAIR SHOP, WHERE IT WAS DETERMINED THAT BOTH ROTO…

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2002 WORKHORSE W22 CUSTOM CHASSIS OWNER. CONSUMER EXPRESSES DISCONTENT REGARDING WORKHORSE ONLY TAKING PARTIAL FINANCIAL RESPONSIBILITY FOR FAULTY BRAKE SYSTEM REPAIRS *TGW THE CONSUMER STATED THE ABS ILLUMINATED AND THERE WAS A VIBRATION DURING BRAKING. THE RV WAS TAKEN TO A REPAIR SHOP, WHERE IT WAS DETERMINED THAT BOTH ROTORS AND CALIPERS HAD VARYING DEGREES OF DAMAGE. THREE OF THE FOUR ROTORS HAD SEVERAL HEAT RELATED STRESS CRACKS THAT RAN COMPLETELY THROUGH THE FACES AND THE REMAINING ROTOR HAD SEVERAL RELATED HEAT STRESS CRACKS. ONE OF THE CALIPER DUST BOOTS HAD BEEN HEATED TO THE POINT OF BREAKING APART AND MANY OTHER DUST BOOTS WERE EXTREMELY HARD. THE CONSUMER STATED HIS RV WAS A PART OF THE RECALL. HOWEVER, WORKHORSE ONLY TOOK FINANCIAL RESPONSIBILITY FOR THE REPLACEMENT OF ONE ROTOR AND ONE CALIPER; PARTS ONLY. *JB

NHTSA ODI #10336964

23,358 miles · Jun 9, 2010
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 FLEETWOOD PACE ARROW RV. THE VEHICLE WAS EQUIPPED WITH A WORKHORSE CHASSIS W22. WHILE THE CONTACT WAS DRIVING APPROXIMATELY BETWEEN 50-50 MPH, PRESSURE WAS APPLIED TO THE BRAKES WITH A DELAY RESPONSE. THE VEHICLE WAS ABLE TO CONTINUE IN OPERATION. THE FAILURE OCCURRED INTERMITTENT. THE CONTACT RECEIVE…

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TL*THE CONTACT OWNS A 2002 FLEETWOOD PACE ARROW RV. THE VEHICLE WAS EQUIPPED WITH A WORKHORSE CHASSIS W22. WHILE THE CONTACT WAS DRIVING APPROXIMATELY BETWEEN 50-50 MPH, PRESSURE WAS APPLIED TO THE BRAKES WITH A DELAY RESPONSE. THE VEHICLE WAS ABLE TO CONTINUE IN OPERATION. THE FAILURE OCCURRED INTERMITTENT. THE CONTACT RECEIVED A RECALL NOTIFICATION REGARDING THE HYDRAULIC BRAKES. THE NHTSA CAMPAIGN ID NUMBER WAS 04V084000. THE MANUFACTURER HAD NOT PROVIDED A REMEDY FOR THE RECALL DEFECT AT THE TIME OF THE COMPLAINT. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED FOR THE BRAKE MALFUNCTION. THE CONTACT HAD CONCERN OF THE SAFETY ISSUE INVOLVED. THE FAILURE MILEAGE WAS 23,358. UPDATED 07/29/10 *BF UPDATED 07/30/10*JB

NHTSA ODI #10335441

18,000 miles · May 14, 2010
Service Brakes, Hydraulic

TL* THE CONTACT OWNS A 2002 WORKHORSE W22 CHASSIS RV. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF NHTSA RECALL CAMPAIGN ID NUMBER 04V084000 (SERVICE BRAKES, HYDRAULIC) IN DECEMBER 2009, YET THE DEALER ADVISED THE PARTS NEEDED TO MAKE THE REPAIRS WERE NOT YET AVAILABLE. THE MANUFACTURER STATED THAT THEY WERE REDESIGNING …

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TL* THE CONTACT OWNS A 2002 WORKHORSE W22 CHASSIS RV. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF NHTSA RECALL CAMPAIGN ID NUMBER 04V084000 (SERVICE BRAKES, HYDRAULIC) IN DECEMBER 2009, YET THE DEALER ADVISED THE PARTS NEEDED TO MAKE THE REPAIRS WERE NOT YET AVAILABLE. THE MANUFACTURER STATED THAT THEY WERE REDESIGNING THE CHASSIS WHICH CAUSED THE RECALL REMEDY TO BE DELAYED. THE CONTACT ALSO ADVISED THE MANUFACTURER THAT FIVE UNSUCCESSFUL ATTEMPTS WERE PREVIOUSLY MADE TO REPAIR THE BRAKES. THE MANUFACTURER STATED THAT THEY WOULD REIMBURSE HIM FOR THE REPAIRS; HOWEVER, HE HAD NOT BEEN REIMBURSED WHEN THE COMPLAINT WAS FILED. HE MADE SEVERAL ATTEMPTS TO CONTACT WORKHORSE TO NO AVAIL. THE CONTACT WAS DISPLEASED WITH THE FACT THAT IT HAS TAKEN OVER A YEAR FOR A SAFETY RECALL TO BE ADDRESSED. THE FAILURE MILEAGE WAS APPROXIMATELY 18,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 40,000.

NHTSA ODI #10330403

Mileage unknown · Apr 30, 2010
Service Brakes, Hydraulic

2002 WORKHORSE W22 CHASSIS RV. *DT THE CONSUMER STATED THE BRAKES ON THE RV LOCKED UP AND IS SEEKING REIMBURSEMENT SINCE A RECALL HAD BEEN ISSUED.

NHTSA ODI #10313187

Mileage unknown · Apr 19, 2010
Service Brakes, Hydraulic

2002 HOLIDAY RAMBLER. WORKHORSE W22 CHASSIS 2002. CONSUMER STATES PROBLEMS WITH THE BRAKES. *TGW THE CALIPERS AND ROTORS HAD TO BE REPLACED TWICE. WORKHORSE STATED THEY DIDN'T HAVE THE PROPER PARTS TO FIX THE PROBLEM. THEY PAID FOR HAVING THE PROBLEM FIXED THE FIRST TIME, BUT THEY REFUSED TO PAY THE SECOND TIME. ACCORDING TO …

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2002 HOLIDAY RAMBLER. WORKHORSE W22 CHASSIS 2002. CONSUMER STATES PROBLEMS WITH THE BRAKES. *TGW THE CALIPERS AND ROTORS HAD TO BE REPLACED TWICE. WORKHORSE STATED THEY DIDN'T HAVE THE PROPER PARTS TO FIX THE PROBLEM. THEY PAID FOR HAVING THE PROBLEM FIXED THE FIRST TIME, BUT THEY REFUSED TO PAY THE SECOND TIME. ACCORDING TO WORKHORSE, THEY REFUSED TO PAY, BECAUSE THE CONSUMER EXPERIENCED THE PROBLEM WHILE DRIVING DOWN A MOUNTAIN. THE CONSUMER STATED THE CALIPERS DRAGGED WHICH CAUSED THE ROTORS TO HEAT UP WHICH RESULTED IN THEM CRACKING. THE CRACKED ROTORS CAUSED THE FRONT OF THE RV TO SHIMMY WHEN GOING DOWNHILL. *JB

NHTSA ODI #10325319

54,000 miles · Apr 15, 2010
Service Brakes, HydraulicFire

FAULTY BRAKING SYSTEM ON WORKHORSE RV CHASSIS ABS ANTILOCK SYSTEM. *TR

NHTSA ODI #10325812

15,635 miles · Mar 16, 2010
Service Brakes, HydraulicSuspension

MULTI-FAILURES OF THE BRAKING SYSTEM ON MY 2002 WORKHORSE W-22 CHASSIS. ALL FOUR CALIPERS HAVE BEEN REPLACED AS WELL AS FRONT WHEEL BEARING AND SEALS DUE TO THE EXTREME HEAT GENERATED WHEN THE SYSTEM FAILED. THIS OCCURRED IN JULY 1ST 2007, JULY 23,2007 AND FEB. 4 2008, .WHEN FAILURES OCCURRED THE MOTOR HOME WAS GOING SLOW ENO…

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MULTI-FAILURES OF THE BRAKING SYSTEM ON MY 2002 WORKHORSE W-22 CHASSIS. ALL FOUR CALIPERS HAVE BEEN REPLACED AS WELL AS FRONT WHEEL BEARING AND SEALS DUE TO THE EXTREME HEAT GENERATED WHEN THE SYSTEM FAILED. THIS OCCURRED IN JULY 1ST 2007, JULY 23,2007 AND FEB. 4 2008, .WHEN FAILURES OCCURRED THE MOTOR HOME WAS GOING SLOW ENOUGH SO THAT A CRASH DID NOT OCCUR. A RECALL ACCORDING TO NHTSA 09V110000 HAS BEEN SET UP BUT TALKING TO WORKHORSE TECHNICAL AND BOSH IT (THE RECALL) HAS NOT FINALIZED EVEN THOUGH THE FIX IS NOW KNOWN (MAY 2009 INTERM NOTICE #2). BELOW IS ONE OF THE NOTES THAT I WROTE TO WORKHORSE: ON 3/11/2010 11:57:42 AM, NONE WROTE: MY MH VIN --XXXXXXX RECEIVED A INTERM NOTICE ON THE ABOVE BRAKE CAMPAIGN BUT WHEN I WENT TO MY INTERNET PAGE MY MOTORHOME IN THE WORKHORSE.COM SECTION I NOTICED THAT IN THE AREA FOR OPEN CAMPAIGNS IT WAS NOT LISTED. CAN YOU EXPLAIN WHY? EMAIL ME OR CALL ME AT XXXXXXXXXX. [XXX] AND THE REPLY FROM WORKHORSE TECHNICAL WHICH STATES: "ON 3/11/2010 12:31:28 PM, WORKHORSE SUPPORT WROTE: THANK YOU VERY MUCH FOR YOUR QUESTION. THE RECALL HAS NOT 'OFFICIALLY' BEEN RELEASED. THE LETTERS THAT WERE SENT WERE INTERIM LETTERS NOTIFYING OWNERS OF THE POTENTIAL PROBLEM. WE ARE REQUIRED TO HAVE 50% OF THE PARTS ON THE SHELF BEFORE WE CAN ISSUE THE OFFICIAL RECALL. WE ARE WORKING ON ADDING A PAGE TO OUR WEBSITE WITH NOTICES AND INFORMATION. PLEASE CONTINUE TO WATCH OUR WEBSITE FOR THE PAGE TO GO LIVE." ALONG WITH THIS I CALLED ELIE AZZI DIRECTOR, PRODUCT WARRANTY BOSCH BRAKING SYSTEMS CORPORATION 401 NORTH BENDIX DRIVE SOUTH BEND, INDIANA 46628 PHONE: 574-237-3104 WHO INFORMED ME THAT BOSCH HAS NOT STARTED TO RETOOL TO MAKE THE NEEDED PARTS BECAUSE OF SOME RIFF BETWEEN WORKHORSE AND NHTSA. TO ALL OF THIS I AM WONDERING IF THERE IS A RECALL AND IS THERE ANY REASON TO THINK THAT WORKHORSE WILL LIVE BY IT. IF YOU NEED THE WRITTEN NOTE FROM WORKHORSE PLEASE SEND ME A PLACE TO SEND IT AND I WILL COMPLY. *TR

NHTSA ODI #10320294

Mileage unknown · Mar 12, 2010
Service Brakes, Hydraulic

WORKHORSE W22 CHASSIS. 2002 FLEETWOOD BOUNDER. CONSUMER EXPRESSES DISCONTENT WITH DATE OF RECALL AS HIS PROBLEMS BEGAN ONE MONTH PRIOR. *TGW THE CONSUMER STATED HE DID DETECT A BURNING ODOR ON SEVERAL OCCASIONS. THE CONSUMER WAS INFORMED HE NEEDED NEW CALIPERS, THE ABS AND REAR BRAKES WERE HEAVILY BURNED, THE ROTORS, PADS AND…

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WORKHORSE W22 CHASSIS. 2002 FLEETWOOD BOUNDER. CONSUMER EXPRESSES DISCONTENT WITH DATE OF RECALL AS HIS PROBLEMS BEGAN ONE MONTH PRIOR. *TGW THE CONSUMER STATED HE DID DETECT A BURNING ODOR ON SEVERAL OCCASIONS. THE CONSUMER WAS INFORMED HE NEEDED NEW CALIPERS, THE ABS AND REAR BRAKES WERE HEAVILY BURNED, THE ROTORS, PADS AND SEALS HAD WORN OUT. ALSO, THE FLUID IN THE LINES AND MASTER CYLINDER WERE EXTREMELY DIRTY. *JB

NHTSA ODI #10318652

30,000 miles · Feb 24, 2010
Service Brakes, Hydraulic

NOVEMBER 16, 2007 EA07016 WAS OPENED. I STILL (2/24/2010) CAN'T USE MY VEHICLE AS WORKHORSE HAS NOT SCHEDULED ANY REPAIRS YET. WHY ARE YOU LETTING THEM GET AWAY WITH THIS. THE PROBLEM IS KNOWN AND IS A SAFETY ISSUE. *TR

NHTSA ODI #10313951

Mileage unknown · Jan 25, 2010
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 WORKHORSE W22 CHASSIS RECREATIONAL VEHICLE. HE STATED HE RECEIVED A RECALL LETTER FOR HIS VEHICLE IN APRIL 2009 INVOLVING SERVICE BRAKES (SEE NHTSA ACTION NUMBER: EA07016, NHTSA CAMPAIGN ID NUMBER: 09V110000: SERVICE BRAKES-HYDRAULIC). THE RECALL STATED A REMEDY WAS CURRENTLY NOT AVAILABLE AND THAT OWN…

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TL*THE CONTACT OWNS A 2002 WORKHORSE W22 CHASSIS RECREATIONAL VEHICLE. HE STATED HE RECEIVED A RECALL LETTER FOR HIS VEHICLE IN APRIL 2009 INVOLVING SERVICE BRAKES (SEE NHTSA ACTION NUMBER: EA07016, NHTSA CAMPAIGN ID NUMBER: 09V110000: SERVICE BRAKES-HYDRAULIC). THE RECALL STATED A REMEDY WAS CURRENTLY NOT AVAILABLE AND THAT OWNERS WILL BE NOTIFIED BY MAIL WHEN PARTS ARE AVAILABLE AND THAT OWNERS SHOULD CONTACT WORKHORSE AT 877-246-7731, HOWEVER THE MANUFACTURER REFERRED HIM TO THE NHTSA INSTEAD. WORKHORSE STATED THAT THEY WERE NOT SURE WHEN THE PARTS WOULD BE AVAILABLE. THE MANUFACTURER OF THE PART WHICH IS BOSCH ZOPS WAS UNABLE TO PROVIDE ANY INFORMATION REGARDING THE AVAILABILITY OF THE PART. THERE ARE NO FAILURES AT THE TIME. THE CURRENT MILEAGE WAS 31,000. UPDATED 03/01/10 *BF UPDATED 06/30/10.*JB

NHTSA ODI #10302198

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.