IllustrationOVERHEATING BRAKE PROBLEMS ON WORKHORSE W22 MOTORHOME CHASSIS (2004) 3RD TIME THIS HAS OCCURED. TWICE ON DIFFERENT WHEELS. *TR
2004 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
450–25K
1825–50K
150–75K
075–100K
0100–150K
0150K+
64 reports with mileage · 28 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 74 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
0 crash reports3 fire reports0 injury reports
Service Brakes, Hydraulic complaints
74 reportsTHE LEFT REAR BRAKES LOCKED-UP CAUSING SMOKE TO AND THE STRONG ODOR OF BRAKE MATERIAL. I REMOVED THE CALIPER AND PUSHED THE PISTONS BAKE INTO THE CALIPER. THIS IS THE FIRST INCIDENT WITH THE BRAKES IN 23,000 MILES, BUT HAS BEEN AN ISSUE WITH THE WORKHORSE W-22 CHASSIS. *TR
MY WORKHORSE BRAKES WENT OUT, I ONLY HAD 12,000 MILES AT THE TIME ON MY NEW MOTORHOME. *TR
I HAD A PROBLEM AND COMPLAINT WITH THE BRAKES ON OUR WINNEBAGO MOTORHOME JUST AS DESCRIBED IN YOUR NHTSA ACTION EA07016. IT WAS DIFFICULT TO DUPLICATE JUST AS YOUR INVESTIGATION HAS FOUND. THIS FIRST HAPPENED IN NOVEMBER 2007 AND AGAIN IN APRIL 2008. I FOUND AN INDEPENDENT MOTORHOME REPAIR SHOP THAT HAD SEEN THIS COMPLAINT WI…
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I HAD A PROBLEM AND COMPLAINT WITH THE BRAKES ON OUR WINNEBAGO MOTORHOME JUST AS DESCRIBED IN YOUR NHTSA ACTION EA07016. IT WAS DIFFICULT TO DUPLICATE JUST AS YOUR INVESTIGATION HAS FOUND. THIS FIRST HAPPENED IN NOVEMBER 2007 AND AGAIN IN APRIL 2008. I FOUND AN INDEPENDENT MOTORHOME REPAIR SHOP THAT HAD SEEN THIS COMPLAINT WITH 2 PRIOR UNITS AND HAD REPAIRED THEM. KEN MEADS WITH MOTORHOME SERVICE IN HOT SPRINGS, ARKANSAS SEEMS VERY VERSED IN THIS PROBLEM. HIS NUMBER IS 501-609-0145. I AM NOT HAPPY WITH WORKHORSE OR BOSCH AS THEY SEEM TO THINK THIS IN NOT THEIR PROBLEM. I AM LOOKING FORWARD TO SOME TYPE OF RESOLUTION TO THIS PROBLEM AND RE-IMBURSEMENT OF MY EXPENSES FOR REPAIR. *TR
FRONT RIGHT BRAKE CALIPER LOCKED UP HEATING ROTOR AND DAMAGING PADS, ROTOR, AND ABS SENSOR. *TR
2004 WORKHORSE W22 MOTORHOME CHASSIS. RIGHT REAR BRAKE SHOES NOT RELEASING FROM ROTOR CAUSING BRAKES TO OVER HEAT. DAMAGE UNKNOWN. RV SCHEDULED FOR INSPECTION MAY 6, 2008. 6500 MILES. DRIVEN ONLY OCCASIONALLY. *TR
BRAKES LOCKED UP ON MY 2004 WORKHORSE W22 CHASSIS. I HAD TO REPLACE ALL 4 CALIPER, BRAKE PADS AND ALL 4 ABS WHEEL SENSORS. *TR
RIGHT REAR BRAKE CALIPER OVER HEATING. *TR
BRAKE FAILURE ON 2004 WORKHORSE 22 CHASSIS WITH LESS THAN 22,000 MILES. LEFT REAR CALIPER LOCKED UP, MASTER CYLINDER FLUID BOILED OVER, ABS SENSOR MELTED. BOTH REAR CALIPERS REPLACED, ALL HOSES, ABS SENSORS, PADS, WHEEL BEARINGS. NO ACCIDENT, INJURIES OR FIRE. THIS CHASSIS IS ON A 2004 PACE ARROW MOTOR HOME. WE WERE ABLE TO …
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BRAKE FAILURE ON 2004 WORKHORSE 22 CHASSIS WITH LESS THAN 22,000 MILES. LEFT REAR CALIPER LOCKED UP, MASTER CYLINDER FLUID BOILED OVER, ABS SENSOR MELTED. BOTH REAR CALIPERS REPLACED, ALL HOSES, ABS SENSORS, PADS, WHEEL BEARINGS. NO ACCIDENT, INJURIES OR FIRE. THIS CHASSIS IS ON A 2004 PACE ARROW MOTOR HOME. WE WERE ABLE TO GET INTO AN RV PARK WITHIN A MILE BY PUMPING BRAKES. ALL PARTS ARE AVAILABLE, WITH THE EXCEPTION OF CALIPERS WHICH WERE EXCHANGED FOR CORE CHARGE. *TR
2004 WORKHORSE W-22 CHASSIS FRONT BRAKE FAILURE. WORKHORSE WILL NOT ADMIT THEY HAVE A PROBLEM, AND WILL NOT ASSIST ME IN FIXING THEM. 22K MILES ON CHASSIS AND THEY SAY I MUST PAY FOR REPAIRS. THEY SHOULD BE SUED FOR SUCH POOR BUSINESS ETHICS. LOCAL DEALER ADMITS TO REPAIRING THIS TYPE PROBLEM A MINIMUM OF 5 TIMES A MONTH! W…
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2004 WORKHORSE W-22 CHASSIS FRONT BRAKE FAILURE. WORKHORSE WILL NOT ADMIT THEY HAVE A PROBLEM, AND WILL NOT ASSIST ME IN FIXING THEM. 22K MILES ON CHASSIS AND THEY SAY I MUST PAY FOR REPAIRS. THEY SHOULD BE SUED FOR SUCH POOR BUSINESS ETHICS. LOCAL DEALER ADMITS TO REPAIRING THIS TYPE PROBLEM A MINIMUM OF 5 TIMES A MONTH! WILL COST ME 2-3000 DOLLARS OUT OF MY POCKET. POOR DESIGN, WITH NUMEROUS ACCOUNTS OF FAILURES, THEY SHOULD HAVE TO PAY FOR REPAIRS! *TR
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.
06V225000 · Engine And Engine Cooling
Jun 20, 2006
ON CERTAIN MOTOR HOME AND TRUCK CHASSIS EQUIPPED WITH GENERAL MOTORS 8.1L V8 ENGINES, IMPROPER HARDENING DURING THE HEAT TREATMENT PROCESS CAN CAUSE THE FUEL RAIL PULSE DAMPER RETAINER CLIP TO FRACTURE, RESULTING IN INADEQUATE RETENTION OF THE DAMPER. IF THE DAMPER BECOMES LOOSE, FUEL COULD BE PUMPED BY THE FUEL PUMP INTO THE UNDER HOOD AREA.
Consequence & remedy
Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.
Remedy: DEALERS WILL REPLACE THE FUEL RAIL PULSE DAMPER RETAINER CLIPS ON THESE ENGINES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 1, 2006. OWNERS MAY CONTACT WORKHORSE AT 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
1EA07016 · 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.