2000 Workhorse W20 problems

What is wrong

On certain motorhome chassis equipped with bosch zops, the pads can drag on the rotor surface due to the pin slide.

Risk

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.

Recall number 04V084000 · Recall details

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.

EA07016

On june 25, 2007, the office of defects investigation (odi) opened a preliminary evaluation to investigate alleged overheating disc brake calipers and poor brake performance in model year (my) 2000-2005 workhorse chassis recreational vehicles.currently odi is aware of 651 specific complaints on the subject vehicles (odi and workhorse complaint population).odi analysis of the warranty and complaint data furnished by workhorse on september 11, 2007, in response to odi's information request indicates a dramatic drop in brake related complaints after the may 2004 build date.at that time, workhorse incorporated into production zerk fittings and greasing of the brake master cylinder's bell crank linkage.odi is also aware of 3,782 unique warranty counts related to the alleged defect in the subject population.a review of the warranty claims reveals that of the claims filed, only 88 were submitted on vehicles produced after the may 2004 production line change (addition of zerk fittings).odi intends to obtain an understanding of why there are seemingly significant differences in the complaint data and warranty claims before and after the may 2004 design change and the safety consequences of the pre-change design. This investigation has been upgraded to an engineering analysis (ea07-016) for further investigation.

PE07032