2002 BOUNDER WITH CHEVY WORKHORSE CHASSIS BRAKE SYSTEM FAILURE. *NJ THE CONSUMER WAS INFORMED THE FRONT CALIPER ON THE PASSENGER SIDE HAD SEIZED AND DESTROYED ALL THE PREVIOUS BRAKE WORK THE CONSUMER HAD DONE 56 MILES AGO. THE LEFT FRONT OIL SEAL WAS LEAKING. *JB
2002 Workhorse W22
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all W22 years →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.
What owners actually said
67 reportsCOMING HOME ON THE 405 FREEWAY IN LOS ANGLES IN STOP AND GO TRAFFIC, MY RIGHT FRONT CALIPER APPARENTLY STUCK ON. ABOUT 2 MILES FROM HOME THE ABS LIGHT CAME ON AND I COULD SMELL THE BRAKES. I WENT ON HOME AND THE RIGHT FRONT WHEEL WAS SMOKING. I LET IT COOL. SINCE THEN I HAVE REPLACED THE RIGHT FRONT CALIPER, THE BRAKE LINE AND T…
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COMING HOME ON THE 405 FREEWAY IN LOS ANGLES IN STOP AND GO TRAFFIC, MY RIGHT FRONT CALIPER APPARENTLY STUCK ON. ABOUT 2 MILES FROM HOME THE ABS LIGHT CAME ON AND I COULD SMELL THE BRAKES. I WENT ON HOME AND THE RIGHT FRONT WHEEL WAS SMOKING. I LET IT COOL. SINCE THEN I HAVE REPLACED THE RIGHT FRONT CALIPER, THE BRAKE LINE AND THE ABS SENSOR. ALL OF THE OTHER CALIPERS APPEAR TO BE OK. *TR
TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING APPROXIMATELY 10 MPH IN A RESIDENTIAL COMMUNITY, THE BRAKE PEDAL EXTENDED TO THE FLOOR. THE VEHICLE FAILED TO STOP AND COASTED THE REST OF THE WAY TO ITS DESTINATION. THE VEHICLE WAS TOWED TO A DEALER. THE CURRENT AND FAILURE MILEAGES WERE 40,000. UPDATED 11/07/08 *B…
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TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING APPROXIMATELY 10 MPH IN A RESIDENTIAL COMMUNITY, THE BRAKE PEDAL EXTENDED TO THE FLOOR. THE VEHICLE FAILED TO STOP AND COASTED THE REST OF THE WAY TO ITS DESTINATION. THE VEHICLE WAS TOWED TO A DEALER. THE CURRENT AND FAILURE MILEAGES WERE 40,000. UPDATED 11/07/08 *BF THE FRONT BRAKES LOCKED UP AND THE PEDAL WENT TO THE FLOOR. THE ABS LIGHT ILLUMINATED. THE CALIPERS LOCKED UP AND DAMAGED THE FLEX HOSE AND ABS SENSOR. UPDATED 11/13/08. *JB
WHILE DRIVING DOWN THE ROAD, THE ENGINE JUST SHUTS DOWN. THIS HAPPENS AT ANYWHERE FROM 2 TO 10 MILES AFTER STARTING DOWN THE HIGHWAY. THIS HAS HAPPENED A TOTAL OF FOUR TIMES TO ME. IT ACTED AS IF THE IGNITION IS TURNED OFF. UPON THE SECOND SHUT DOWN, A SCAN TOOL WAS USED AND PRODUCED THE CODE INDICATING THERE WAS A MALFUNCTION I…
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WHILE DRIVING DOWN THE ROAD, THE ENGINE JUST SHUTS DOWN. THIS HAPPENS AT ANYWHERE FROM 2 TO 10 MILES AFTER STARTING DOWN THE HIGHWAY. THIS HAS HAPPENED A TOTAL OF FOUR TIMES TO ME. IT ACTED AS IF THE IGNITION IS TURNED OFF. UPON THE SECOND SHUT DOWN, A SCAN TOOL WAS USED AND PRODUCED THE CODE INDICATING THERE WAS A MALFUNCTION IN THE CRANKSHAFT POSITION SENSOR. AFTER PULLING OFF THE ROAD AND ALLOWING THE ENGINE TO SIT FOR ABOUT 30 SECONDS THE ENGINE CAN BE RESTARTED AND DRIVEN FOR AS FAR AS 125 MILES WITH NO FURTHER PROBLEM. EACH AND EVERY TIME SINCE THE INITIAL START OF THE PROBLEM, THE PROBLEM HAS OCCURRED EACH TIME THE VEHICLE WAS DRIVEN. THIS ENGINE IS A 8.1 L CHEVROLET ENGINE INSTALLED IN A 2002 RV WITH A CHASSIS BUILD DATE OF 9/28/01. ALL OF THE SYMPTOMS ARE EXACTLY AS NOTED IN THE RECALL CAMPAIGN ISSUED BY GM. GM RECALL NO. 06083. THE RV CHASSIS MANUFACTURER HAS REFUSED TO ACKNOWLEDGE THAT GM HAS A RECALL FOR THIS REASON, AND TO PROVIDE ME WITH THE CRANKSHAFT POSITION SENSOR FOR ME TO REPLACE. I'M AFRAID TO DRIVE THE VEHICLE TO THE DEALER TO GET IT LOOKED AT AND THEY TOLD ME THAT BECAUSE IT IS AN INTERMITTENT PROBLEM, THEY WOULD HAVE TO DRIVE THE VEHICLE TO REPRODUCE THE PROBLEM AND THEY DIDN'T WANT TO DO THAT. ONCE THE ENGINE SWITCH IS TURNED OFF AND THEN BACK ON THE CODE DOES NOT APPEAR, MAKING IT DIFFICULT FOR SERVICE TECH"S TO DIAGNOSE THE PROBLEM. NO ACCIDENTS OR DEATHS HAVE RESULTED FROM THIS PROBLEM BUT THIS COULD BE A SEVERE SAFETY ISSUE. *TR
TL*THE CONTACT OWNS A 2002 WORKHORSE W22 . WHILE DRIVING BETWEEN 20-30 MPH, THE BRAKES FAILED. THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT PULLED OFF THE ROAD INTO A GRASSY AREA, WHICH SLOWED DOWN THE VEHICLE AND EVENTUALLY LED TO A COMPLETE STOP. HE PULLED THE VEHICLE BACK ONTO THE ROAD AND DROV…
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TL*THE CONTACT OWNS A 2002 WORKHORSE W22 . WHILE DRIVING BETWEEN 20-30 MPH, THE BRAKES FAILED. THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT PULLED OFF THE ROAD INTO A GRASSY AREA, WHICH SLOWED DOWN THE VEHICLE AND EVENTUALLY LED TO A COMPLETE STOP. HE PULLED THE VEHICLE BACK ONTO THE ROAD AND DROVE TO A SHOPPING CENTER. THE BRAKES WERE PERFORMING BETTER, BUT DISPLAYED VERY LITTLE STOPPING POWER. THE VEHICLE WAS TOWED TO A DEALER AND THEY STATED THAT THE PASSENGER SIDE CALIPER HAD BEEN LOCKED UP FOR QUITE A WHILE. THE DEALER REPLACED THE BEARING SEAL ON THE FRONT PASSENGER SIDE WHEEL, BRAKE PADS, FRONT AND REAR ROTORS, AND THE FRONT AND REAR CALIPERS. AFTER THE REPAIRS WERE MADE, THE CONTACT DISCOVERED AN INVESTIGATION RELATING TO THE SERVICE BRAKES, HYDRAULIC, WHICH DESCRIBED THE SAME FAILURES HE WAS EXPERIENCING. THE NHTSA CAMPAIGN ID NUMBER WAS UNKNOWN. THE FAILURE MILEAGE WAS 40,856 AND CURRENT MILEAGE WAS 43,926. UPDATED 11/7/08 *CN THE CALIPERS LOCKED UP, WHICH CAUSED THE ROTORS TO WARP. UPDATED 11/13/08. *JB
TL*THE CONTACT OWNS A 2002 NEWMAR MOUNTAIN AIRE WITH A WORKHORSE CHASSIS. THE CONTACT STATED THAT THERE WERE BRAKE SEIZURES WITH HIS BRAKE CALIPERS. WHILE DRIVING 30 MPH, THE BRAKES LOCKED UP AND CAUSED THE VEHICLE TO PULL TO THE RIGHT. THE FAILURE MELTED THE ABS WIRING AND NEARLY STARTED A FIRE. THE CONTACT ALSO STATED THAT…
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TL*THE CONTACT OWNS A 2002 NEWMAR MOUNTAIN AIRE WITH A WORKHORSE CHASSIS. THE CONTACT STATED THAT THERE WERE BRAKE SEIZURES WITH HIS BRAKE CALIPERS. WHILE DRIVING 30 MPH, THE BRAKES LOCKED UP AND CAUSED THE VEHICLE TO PULL TO THE RIGHT. THE FAILURE MELTED THE ABS WIRING AND NEARLY STARTED A FIRE. THE CONTACT ALSO STATED THAT THERE WAS AN ONGOING ISSUE WITH THE MANUFACTURER REGARDING THE BRAKES. THE REPAIR CENTER STATED THAT THE REPAIR WOULD COST APPROXIMATELY $3,000. THE DEALER STATED THAT THE FAILURE WOULD RECUR EVEN IF THE REPAIR WAS MADE. THE CURRENT MILEAGE WAS APPROXIMATELY 31,000 AND FAILURE MILEAGE WAS APPROXIMATELY 30,500. UPDATED 11/19/08. *JB
1. RANDOM LOCK UP OF VEHICLE BRAKES 2. OCCURRED SEPTEMBER 2006 AND AGAIN IN AUGUST 2008. EXTREME VEHICLE VIBRATION AND LOSS OF STEERING. BRAKES SMOKE AND BECOME EXTREMELY HOT. 3. VEHICLE CHECKED BY LES SCHWAAB TIRE STORE AND AUTHORIZED GM REPAIR CENTER. CHARGED FOR INSPECTION. NEITHER SHOP COULD DIAGNOSE CAUSE OR REPAIR NE…
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1. RANDOM LOCK UP OF VEHICLE BRAKES 2. OCCURRED SEPTEMBER 2006 AND AGAIN IN AUGUST 2008. EXTREME VEHICLE VIBRATION AND LOSS OF STEERING. BRAKES SMOKE AND BECOME EXTREMELY HOT. 3. VEHICLE CHECKED BY LES SCHWAAB TIRE STORE AND AUTHORIZED GM REPAIR CENTER. CHARGED FOR INSPECTION. NEITHER SHOP COULD DIAGNOSE CAUSE OR REPAIR NEEDED. *TR
HAD BRAKE RECALL IN 2/06. BRAKES NEARLY FAILED 7/08 ON TRIP OUT WEST. ABS SENSOR BAD, FRONT BRAKE PADS BAD, AND LEFT FRONT CALIPER BAD. THIS CORRESPONDS TO TROUBLES OTHER DRIVERS HAVE HAD WITH THIS SYSTEM. *TR
COMING HOME FROM CAMPING,IN TRAFFIC WHEN ABS LIGHT COMES ON. THERE'S A SMELL OF BURNING BRAKES. RV SEEMS TO BE UNDER A HEAVY LOAD. AFTER A FEW STOPS BRAKING GETS HARDER. BY THE TIME I MAKE IT HOME ALMOST A COMPLETE BRAKE FAILURE. BRAKE PEDAL GOES TO THE FLOOR. PUMPING THE BRAKES MAINTAIN SOME STOPPING CONTROL. PARKED RV AND S…
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COMING HOME FROM CAMPING,IN TRAFFIC WHEN ABS LIGHT COMES ON. THERE'S A SMELL OF BURNING BRAKES. RV SEEMS TO BE UNDER A HEAVY LOAD. AFTER A FEW STOPS BRAKING GETS HARDER. BY THE TIME I MAKE IT HOME ALMOST A COMPLETE BRAKE FAILURE. BRAKE PEDAL GOES TO THE FLOOR. PUMPING THE BRAKES MAINTAIN SOME STOPPING CONTROL. PARKED RV AND SEEKING HELP. *TR
TL*THE CONTACT OWNS A 2002 WORKHORSE W22 TRAILER. WHEN THE CONTACT EXITED THE VEHICLE, HE SMELLED THE BRAKES AND WHEEL BEARINGS BURNING. THE CONTACT REMOVED THE WHEEL AND NOTICED OIL FROM THE WHEEL BEARING COVERING THE TIRE. THE VEHICLE WAS TAKEN TO THE DEALER AND REPAIRED. IN OCTOBER OF 2007, THE CONTACT SMELLED AN ODOR COM…
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TL*THE CONTACT OWNS A 2002 WORKHORSE W22 TRAILER. WHEN THE CONTACT EXITED THE VEHICLE, HE SMELLED THE BRAKES AND WHEEL BEARINGS BURNING. THE CONTACT REMOVED THE WHEEL AND NOTICED OIL FROM THE WHEEL BEARING COVERING THE TIRE. THE VEHICLE WAS TAKEN TO THE DEALER AND REPAIRED. IN OCTOBER OF 2007, THE CONTACT SMELLED AN ODOR COMING FROM THE REAR BRAKES. THE VEHICLE WAS TAKEN TO THE DEALER, BUT THEY COULD NOT DUPLICATE THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 16,000. UPDATED 04/22/08. *LJ THE CONSUMER WAS TOLD THE REAR BRAKES WOULD NOT BE REPLACED WITH UPGRADED BRAKES. THE CONSUMER STATED THE PROBLEM STILL EXISTS WITH THE BRAKES. THE CHECK ENGINE LIGHT ILLUMINATED. THE CRUISE CONTROL DID NOT COME. UPDATED
Official recalls
209V110000 · 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
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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