2003 Workhorse W22

TL*- THE CONTACT OWNS A 2003 W22 WORKHORSE CHASSIS. WHILE DRIVING THE CHASSIS STARTED TO PULL TO THE RIGHT AND A LOT NOISE WAS HEARD COMING FROM THE BRAKES WHEN APPLY. THE CONTACT MADE AN APPOINTMENT WITH THE DEALERSHIP TO DIAGNOSE THE BRAKES. THE DEALERSHIP STATED THAT THE ABS SYSTEM HAD MALFUNCTIONED DUE TO THE EXTREME HEAT FROM THE BRAKE CALIPERS BEING APPLIED TO THE ROTORS. THE CONTACT FOUND A RECALL VIA THE INTERNET BUT HIS VEHICLE DID NOT FALL INTO THE RECALL PARAMETERS. THE VEHICLE IS CURRENTLY AT THE DEALERSHIP AWAITING REPAIRS. THE CURRENT MILEAGE WAS 28,392 AND FAILURE MILEAGE 28,382.

TL*THE CONTACT OWNS A 2003 WORKHORSE W22 TRAILER. WHILE DRIVING 50 MPH, THE CONTACT SMELLED A BURNING ODOR COMING FROM THE FRONT END OF THE VEHICLE. THE VEHICLE BEGAN TO PULL TO THE RIGHT WHEN THE BRAKES WERE APPLIED. HE PULLED THE VEHICLE OVER AND NOTICED THAT THE FRONT BRAKES WERE VERY HOT. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY DETERMINED THAT THE FRONT BRAKE CALIPERS AND SEALS FAILED. THE VEHICLE WAS REPAIRED. FOUR YEARS LATER, WHILE DRIVING 50 MPH, THE CONTACT SMELLED A STRONG BURNING ODOR COMING FROM THE REAR OF THE VEHICLE. HE EXITED THE VEHICLE TO INSPECT THE FAILURE AND NOTICED THAT THE REAR BRAKES WERE VERY HOT. THE CONTACT IS IN THE PROCESS OF TAKING THE VEHICLE TO THE DEALER FOR INSPECTION AND NOTIFYING THE MANUFACTURER. THE FAILURE MILEAGE WAS 13,548 AND CURRENT MILEAGE WAS 27,835. UPDATED 5/7/09 *CN UPDATED 05/12/09.*JB

TL*THE CONTACT OWNS A 2004 FLEETWOOD PACE ARROW RECREATIONAL VEHICLE ON A 2003 WORKHORSE . THE CONTACT STATED THAT THE PLASTIC FRONT WHEEL BEARINGS AND THE FRONT DISC BRAKES OVERHEATED. IN ADDITION, THE DEALER DISCOVERED THAT THE REAR BRAKES ALSO FAILED. THE VEHICLE HAS NOT YET BEEN REPAIRED. THE FAILURE MILEAGE WAS 11,119 AND CURRENT MILEAGE IS 12,536. UPDATED 04-23-09 *BF THE CONSUMER STATED THE FRONT AXLE PLASTIC OIL CUPS, INNRE AXLE SEALS, ROTORS AND BRAKE PADS WERE DESTROYED BY HEAT. DURING AN VISUAL INSPECTION, IT WAS APPARENT THAT THE REAR BRAKES WERE NOT WORKING DUE TO LACK OF CONTACT BETWEEN THE BRAKE PADS AND ROTORS. THE RV HAS NOT BEEN REAPIRED DUEE TO AN ONGOING INVESTIGATION BY THE CONSUMER. UPATED 05/01/09. *JB

ABS LIGHT CAME ON AND I WENT TO HAVE THE VEHICLE SERVICED. THE SERVICE TECH SHOWED ME THE ROTORS AND CALIPERS. THEY WERE BADLY CRACKED AND OVERHEATED. COST $4700 TO REPAIR. WOULD NOT WARRANTY THEM BECAUSE THE COMPUTER CODE SAID I WAS RIDING THE BRAKES. "FALSE". THEY INSTALLED A ZERK FITTING ON THE SHAFT TO THE BELL CRANK WITHOUT DOCUMENTING IT. *TR

TL*THE CONTACT OWNS A 2003 WORKHORSE CHASSIS W22. WHILE DRIVING APPROXIMATELY 25 MPH, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN THE BRAKE PEDAL WAS DEPRESSED. THE RISK OF A CRASH WAS INCREASED. THE CONTACT IS IN THE PROCESS OF HAVING THE VEHICLE INSPECTED TO DETERMINE THE CAUSE OF THE FAILURE. HE FILED A COMPLAINT WITH THE MANUFACTURER. THE FAILURE AND CURRENT MILEAGES WERE NOT APPLICABLE.

TL*THE CONTACT OWNS A 2003 WORKHORSE W22. WHILE SPORADICALLY DEPRESSING THE BRAKE PEDAL, THE VEHICLE FAILED TO STOP. UPON FURTHER INSPECTION, THE CONTACT NOTICED THAT THE BRAKE FLUID WAS BUBBLING DUE TO EXCESSIVE HEAT EXPOSURE. HE TOOK THE VEHICLE TO THE DEALER BECAUSE THREE OF THE ABS WHEEL SENSORS BURNED OFF AND TWO OF THE ABS SEALS FAILED. THE TECHNICIAN REPLACED THE BRAKE CALIPERS AND THE SEALS AT MORE THAN $1,000. THE MANUFACTURER WOULD NOT ASSIST BECAUSE THERE WAS NO RECALL. THE FAILURE AND CURRENT MILEAGES WERE NOT APPLICABLE. UPDATED 03/27/09 *BF THE CONSUMER STATED ON 2 SEPARATE OCCASIONS, HE HAD TO PULL OVER AND WAIT FOR THE BRAKES TO COOL OFF. THE THIRD TIME, THE BRAKES SEIZED. THE CALIPER WAS REPLACED. UPDATED 04/01/09. *JB

ON 12/4/08 AS WE WERE TRAVELING IN OUR 2003 ALLEGRO BAY MOTORHOME IN STOP AND GO TRAFFIC NEAR MOBILE, AL WE ONCE AGAIN FOR NO APPARENT REASON, STARTED TO SMELL BRAKES BURNING. WITH 26,482 MILES ON OUR COACH, THIS IS OUR THIRD BRAKE FAILURE EVENT IN LESS THAN FOUR MONTHS. I PULLED OVER AS SOON AS POSSIBLE AND CHECKED THE TEMPERATURE OF ALL BRAKE ASSEMBLIES WITH MY INFRARED THERMOMETER WHICH I NOW KEEP AVAILABLE. THE BRAKE CALIPER ON THE FRONT DRIVER'S SIDE MEASURED APPROX. 450 DEGREES. I ALLOWED THE BRAKES TO COOL, THEN PROCEEDED TO THE NEAREST WORKHORSE REPAIR FACILITY (APPROX. 12 MILES). THEY REPLACED BOTH FRONT CALIPERS, BRAKE LINES, PADS AND FLUID. AT MY REQUEST, THEY ALSO CHECKED AND LUBRICATED THE REAR CALIPERS FOR A TOTAL COST OF $1,005.80. THE REPAIR FACILITY KEPT THE OLD PARTS. *TR

WHILE TRAVELING IN OUR RV FOR NO APPARENTLY REASON, WE SUDDENLY BEGAN TO SMELL BURNING BRAKES, THEN THE STEERING BEGAN TO SHIMMY AND VIBRATE. WHEN THE BRAKE WAS APPLIED THE VIBRATION INCREASED. I IMMEDIATELY PULLED OFF AT A SAFE AREA, UNHOOKED MY TOW VEHICLE AND WENT FOR ASSISTANCE. ALL FOUR ROTORS AND BRAKE PADS WERE REPLACED AT A COST OF $2209.89. THIS IS THE FIRST TIME WE HAVE EXPERIENCED ANY PROBLEMS WITH OUR BRAKES AND IT HAPPENED SUDDENLY WITH NO WARNING. THE OLD PARTS WERE SENT BACK AS "CORE" PARTS BY THE REPAIR FACILITY. WE ARE NOW AWARE OF NHTSA EA07-016 INVOLVING BOSCH BRAKE CALIPERS OVERHEATING, CAUSING THE ROTORS TO GO BAD AND BELIEVE OUR WORKHORSE CHASIS WHICH DOES HAVE THIS BRAND OF CALIPERS HAS EXPERIENCED THE SAME PROBLEM AS WAS DESCRIBED IN THIS BULLETIN. UPON COMPLETION OF THIS REPAIR, WE PROCEEDED ON OUR TRIP. ABOUT 75 MILES FARTHER, WE AGAIN SMELLED BRAKES BURNING. WE PULLED OFF THE ROAD AS FAST AS WE COULD AND CALLED OUR ROADSERVICE. THE PASSENGER SIDE FRONT BRAKE WAS SMOKING. THEY SENT OUT A MOBILE REPAIR TECH WHO REMOVED THE TIRE/WHEEL, REMOVED THE CALIPER AND LUBRICATED THE CALIPER SLIDE. THE CALIPER SEEMED TO BE WORKING NORMALLY, HOWEVER, WE ARE AT A LOSS AS TO WHAT ACTUALLY CAUSED OUR PROBLEM AND ARE CONCERNED THAT THE CAUSE HAS NOT BEEN ADDRESSED AND IT WILL REOCCUR. *TR