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2004 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

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

What owners actually said

92 reports
Mileage unknown · Oct 7, 2009
Service Brakes, Hydraulic

CONSUMER WANTS TO BE REIMBURSED FOR THE REPAIR WORK DONE ON THEIR 2004 FLEETWOOD BOUNDER FOR SAFETY RECALL 50901-C. *NJ WHILE DRIVING, THERE WAS AN ODOR OF HOT BRAKES. THE CONSUMER STOPPED AT A WEIGH STATION AND CHECKED THE BRAKES, BUT THEY DIDN'T SEEM VERY HOT. AFTER ABOUT 6 OR 7 MILES, THE ODOR BECAME STRONGER. THE CONSUMER…

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CONSUMER WANTS TO BE REIMBURSED FOR THE REPAIR WORK DONE ON THEIR 2004 FLEETWOOD BOUNDER FOR SAFETY RECALL 50901-C. *NJ WHILE DRIVING, THERE WAS AN ODOR OF HOT BRAKES. THE CONSUMER STOPPED AT A WEIGH STATION AND CHECKED THE BRAKES, BUT THEY DIDN'T SEEM VERY HOT. AFTER ABOUT 6 OR 7 MILES, THE ODOR BECAME STRONGER. THE CONSUMER PULLED OVER AND WHEN CHECKING THE BRAKES, THE ANTI-LOCK SENSOR ON THE DRIVERS SIDE BLEW OUT. THE NEXT DAY, THE RV WAS TAKEN TO A SHOP WHERE IT WAS DISCOVERED THE CALIPERS HAD FROZE AND NEEDED TO BE REPLACED.(WORKHORSE 2004 W22 CHASSIS) *JB

NHTSA ODI #10286488

31,254 miles · Aug 31, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 TIFFIN ALLEGRO BAY MOTOR HOME WITH A W22 WORKHORSE CHASSIS. THE CONTACT STATED THAT DURING APPLICATION THERE IS ABNORMAL HEAT GENERATION AT THE WHEEL END WHICH CAUSES BRAKE DRAG AND STICKING. THIS CAN EVENTUALLY LEAD TO SOFT PEDAL CONDITIONS DUE TO BRAKE FLUID BOIL, AND POSSIBLE EXTENDED STOPPING DIST…

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TL*THE CONTACT OWNS A 2004 TIFFIN ALLEGRO BAY MOTOR HOME WITH A W22 WORKHORSE CHASSIS. THE CONTACT STATED THAT DURING APPLICATION THERE IS ABNORMAL HEAT GENERATION AT THE WHEEL END WHICH CAUSES BRAKE DRAG AND STICKING. THIS CAN EVENTUALLY LEAD TO SOFT PEDAL CONDITIONS DUE TO BRAKE FLUID BOIL, AND POSSIBLE EXTENDED STOPPING DISTANCE INCREASING THE RISK OF A CRASH. HE CONTACTED THE DEALER IN REFERENCE TO RECALL# 09V110000 (SERVICE BRAKES, HYDRAULIC), BUT BECAUSE THE PARTS WERE UNAVAILABLE THE FAILURES HAVE NOT BEEN PROPERLY REMEDIED.. THE FAILURE MILEAGE WAS 31,254. THE CONSUMER STATED HE HAD TO APPLY THE BRAKES WHEN A VEHICLE SUDDENLY PULLED IN FRONT OF HIM. WHEN HE STARTED TO ACCELERATE, HE NOTICED THE RV WASN'T ACCELERATING AND HE IMMEDIATELY PULLED OVER. HE DISCOVERED THE REAR WHEELS WERE EXTREMELY HOT TO TOUCH AND BRAKE FLUID WAS BOILING OUT OF THE RESERVOIR. THE RV WAS INSPECTED AND IT WAS DISCOVERED THAT THE RIGHT REAR CALIPER HAD FROZEN TO THE ROTOR. WORKHORSE AUTHORIZED THE REPLACEMENT OF THE BRAKE SHOES AND CALIPER. UPDATED 09/29/09.*JB UPDATED 01/13/10. *JB

NHTSA ODI #10282400

Mileage unknown · Aug 20, 2009
Service Brakes, Hydraulic

2004 WORKHORSE HAD A PROBLEM WITH THE BRAKES LOCKING UP. *NJ THE CONSUMER TOOK THE RV TO A REPAIR SHOP AND WAS INFORMED TWO OF THE BRAKE CYLINDERS HAD LOCKED UP. WORKHORSE DENIED THE CONSUMERS CLAIM STATING THE DAMAGE WAS NORMAL WEAR. THE MECHANIC, HOWEVER STATED THERE WAS A RECALL REGARDING THIS VERY ISSUE. *JB

NHTSA ODI #10281090

34,060 miles · Aug 5, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 FOUR WINDS INFINITY 35F RV. THE VEHICLE WAS EQUIPPED WITH WORKHORSE CUSTOM CHASSIS BRAKES. WHILE DRIVING APPROXIMATELY 10 MPH, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT EXPERIENCED EXTREME DIFFICULTY SLOWING DOWN THE VEHICLE. SUDDENLY, THE ABS WARNING INDICATOR ILLUMI…

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TL*THE CONTACT OWNS A 2004 FOUR WINDS INFINITY 35F RV. THE VEHICLE WAS EQUIPPED WITH WORKHORSE CUSTOM CHASSIS BRAKES. WHILE DRIVING APPROXIMATELY 10 MPH, THE BRAKE PEDAL EXTENDED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT EXPERIENCED EXTREME DIFFICULTY SLOWING DOWN THE VEHICLE. SUDDENLY, THE ABS WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE PARKING BRAKE WAS ENGAGED AND THE VEHICLE PROCEEDED TO A COMPLETE STOP. THE WARNING INDICATOR REMAINED ILLUMINATED UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE RESUMED OPERATION AFTER BEING PARKED FOR TWO CONSECUTIVE DAYS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION, BUT THEY COULD NOT DETERMINE THE CAUSE OF THE FAILURE. IN ADDITION, THE ROTORS WERE CRACKED. CURRENTLY, THE VEHICLE IS BEING REPAIRED AT THE COST OF $2,500. THE AUTHORIZED DEALER NOTIFIED THE MANUFACTURER CONCERNING THE RECALL REMEDY REPAIR; HOWEVER, THE MANUFACTURER HAS REFUSED TO REPAIR THE VEHICLE BECAUSE THE CALIPER FAILURE HAS NOT YET BEEN CONFIRMED. THE FAILURE AND CURRENT MILEAGES WERE 34,060. UPDATED 09/01/09. *LJ THE SEALS AND CALIPERS WERE REPLACED. THE LEFT FRONT WHEEL WAS DRAGGING AND OVERHEATED. UPDATED 09/09/09*JB

NHTSA ODI #10279496

31,540 miles · Aug 5, 2009
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 ITASCA SUNOVA ON A WORKHORSE CHASSIS. WHILE DRIVING 35 MPH, THE STEERING TIGHTENED UP. WHEN THE CONTACT PULLED INTO THE DRIVEWAY, HE NOTICED SMOKE COMING FROM THE REAR PASSENGER SIDE CALIPER. HE ALLOWED THE RV TO COOL DOWN FOR A FEW DAYS BEFORE DRIVING IT TO THE DEALER. THE DEALER STATED THAT THE …

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TL*THE CONTACT OWNS A 2004 ITASCA SUNOVA ON A WORKHORSE CHASSIS. WHILE DRIVING 35 MPH, THE STEERING TIGHTENED UP. WHEN THE CONTACT PULLED INTO THE DRIVEWAY, HE NOTICED SMOKE COMING FROM THE REAR PASSENGER SIDE CALIPER. HE ALLOWED THE RV TO COOL DOWN FOR A FEW DAYS BEFORE DRIVING IT TO THE DEALER. THE DEALER STATED THAT THE REAR PASSENGER SIDE CALIPER WAS DEFECTIVE, WHICH CAUSED THE BRAKES TO DRAG AND OVERHEAT. THE MANUFACTURER STATED THAT THEY WILL PROVIDE THE CALIPER AND HE WILL PAY FOR THE LABOR. THE FAILURE MILEAGE WAS 31,540 AND CURRENT MILEAGE WAS 31,544. UPDATED 8/28/09 *CN UPDATED 09/04/09.*JB

NHTSA ODI #10279488

Mileage unknown · Jul 22, 2009
Service Brakes, Hydraulic

SAFETY RECALL 50901-C ON 2005 ALLEGRO MOTOR HOME. *NJ THE CONSUMER HAS A 2004 WORKHORSE W22. IN DECEMBER 2008 THE CONSUMER BEGAN TO EXPERIENCE A BRAKE DRAGGING SOUND, SO HE TOOK THE MOTORHOME TO THE DEALER FOR AN INSPECTION. THE SHOP DETERMINED THAT THE BRAKE LININGS WERE BAD, EVEN THE MOTORHOME HAD ONLY 32,000 MILES. THE CALI…

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SAFETY RECALL 50901-C ON 2005 ALLEGRO MOTOR HOME. *NJ THE CONSUMER HAS A 2004 WORKHORSE W22. IN DECEMBER 2008 THE CONSUMER BEGAN TO EXPERIENCE A BRAKE DRAGGING SOUND, SO HE TOOK THE MOTORHOME TO THE DEALER FOR AN INSPECTION. THE SHOP DETERMINED THAT THE BRAKE LININGS WERE BAD, EVEN THE MOTORHOME HAD ONLY 32,000 MILES. THE CALIPERS CONTAINED A LITTLE RUST, AND THEY WERE CLEANED AND RE-INSTALLED. ON JANUARY 6, 2009 THE CONSUMER SMELLED A BURNING SMELL. EXAMINATION OF THE TIRES REVEALED AN OVERHEATED REAR TIRE. THE PROBLEM WAS WITH THE CALIPER, WHICH WAS REPLACED. ON MARCH 29, 2009 THE MOTORHOME BEGAN TO PULL TO THE RIGHT AND THERE WAS A SMELL OF SMOKE. THE CONSUMER PULLED OVER AND DISCOVERED THE RIGHT FRONT TIRE WAS SMOKING AND RED HOT FLUID WAS LEAKING FROM THE WHEEL. THE CONSUMER WENT TO A LOCAL SHOP AND WAS TOLD THE PROBLEM WAS THE CALIPERS. *JB

NHTSA ODI #10277868

20,840 miles · Jul 16, 2009
Service Brakes, Hydraulic

BRAKE FAILURE ON FLEETWOOD 2004 PACE ARROW MOTOR HOME. *TR THE CONSUMER IS SEEKING REIMBURSEMENT FOR THE REPLACEMENT OF THE REAR CALIPERS. 2004 WORKHORSE W22. UPDATED 10/07/09

NHTSA ODI #10276976

42,000 miles · Jul 8, 2009
Service Brakes, Hydraulic

AFTER TWO HOUR TRIP IN AN 04 WINNABAGO W22 CHASIS WE DISCOVERED THE BRAKES WERE DRAGGING AND SUBSEQUENTLY BOILED THE BRAKE FLUID ; BRAKE PEDAL TO THE FLOOR! *TR

NHTSA ODI #10276093

12,800 miles · Jul 6, 2009
Service Brakes, HydraulicFire

TL*THE CONTACT OWNS A 2004 GULF STREAM SUN VOYAGER RV. THE VEHICLE HAS A WORKHORSE W22 CHASSIS. IN JULY OF 2008, THE FRONT DRIVER'S SIDE CALIPER CAUGHT FIRE. THE CALIPER WAS REPLACED. ON MAY 22, 2009, THE CONTACT FELT THE VEHICLE PULLING TO ONE SIDE WHILE DRIVING 65 MPH. SHE PULLED THE VEHICLE OVER AND NOTICED THAT THE REAR…

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TL*THE CONTACT OWNS A 2004 GULF STREAM SUN VOYAGER RV. THE VEHICLE HAS A WORKHORSE W22 CHASSIS. IN JULY OF 2008, THE FRONT DRIVER'S SIDE CALIPER CAUGHT FIRE. THE CALIPER WAS REPLACED. ON MAY 22, 2009, THE CONTACT FELT THE VEHICLE PULLING TO ONE SIDE WHILE DRIVING 65 MPH. SHE PULLED THE VEHICLE OVER AND NOTICED THAT THE REAR PASSENGER SIDE CALIPER WAS OVERHEATING. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY REPLACED THE CALIPER. THE MANUFACTURER FILED A REPORT AND REQUESTED DOCUMENTATION IN ORDER TO CONSIDER PROVIDING REIMBURSEMENT. THE FAILURE MILEAGE WAS 12,800 AND CURRENT MILEAGE WAS 13,889.

NHTSA ODI #10275827

12,505 miles · Jun 30, 2009
Service Brakes, Electric

WORKHORSE MOTOR HOME 2004 REAR LEFT BRAKE CALIPER FAILURE. *TR

NHTSA ODI #10275370

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.

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

1

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.