2nd occurrence of brake sticking / drag during this trip. R rear brake did not release after braking causing drag & overheating. This (and the previous reported incident) occurred after going through a section of in-town stop & go traffic & stop lights. This occurrence was recognized quickly and was not as severe as the previous one. I was able to cool the brakes down and they released.
The worst 2003 Workhorse W20 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
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- Brakes11
Specific symptoms reported on the 2003 Workhorse W20
Recalls 1
Service brakes, hydraulic
- What is wrong
- 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.
- Risk
- 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.
Recall number 09V110000 · Recall details
See all 1 recalls for the 2003 Workhorse W20
Defect investigations
Overheating disc brake caliper
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
Overheated brake calipers
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
What 2003 Workhorse W20 owners say
Most recent owner complaints, unedited.
Brake failure - lockup of front brake caliper / rotor causing overheating and brake failure. No serious injury resulted. Caused trip delay and significant cost to repair replace brake components affected. Dealer inspected and diagnosed significant overheating and cracking of the front rotors and recommended replacement of same and pads & seals at a cost of approx $900. This unit was purchased used with approx 37600 miles at which time the dealer (wh service center) inspected and replace brake pads on all 4 wheels. This unit is stored for several months at a time but has always been inside storage and the unit is not driven in winter weather.
Ltr from congressman bishop on behalf of constituent re an update on an inquiry he previously submitted re w20 and w22 chassis brakes. *nj the consumer stated the rear brake rotors overheated. The boiling brake fluid also lead to the brake failure.
Partial lockup of rear calipers on a 2003 workhorse w-20 chassis on a 2004 fleetwood flair 33r motorhome after traveling approximately 100 miles on relatively flat highway entering traffic with stoplights. After about 10 miles in the stop and go traffic, a slight 'brake smell' was noticed. This was approximately 10 miles from home. I got out and checked the wheels and both rear wheels were hot to the touch. At approximately 1 mile from home the ABS light came on and the brake pedal went to the floor. When this happened, I pumped the pedal a few times and had brakes. I limped home in this condition. Parked at home I noticed the master cylinder was hot, the brake line to the rear brakes was hot, a sensor had melted off the right rear dual, and a length (approx. 18 inches) of fine, coiled, copper wire was hanging from the caliper. To me it looked like it came out of the melted sensor. The left wheel was hot, and nothing was melted. An appointment was made to get it looked at on 8/26/08.
While my 2003 fleetwood southwind motor home on a workhorse chassis was in for a recall on the instrument cluster (ABS) I was informed that my brake fluid had over heated and the brake system required replacement (calipers, pads, rotors). According to the dealer the fluid overheated, turned to a jelly and would not allow the pistons to retract after the brakes had been applied. Worhorse was contacted by dealer and they refused to acknowledge there was an issue with the brakes. I retained 2 of the brake calipers after repairs were complete. Related to the federal safety agency ea07016.
We have a 2003 motorhome with a w20 workhorse frame. I have lost the hydraulic brakes due to the fluid boiling twice during normal driving on level roads (no hills or mountains) both times the heat destroyed the ABS wheel sensors.
Rear brakes overheating. No complete failure. Only caused loss of rv vacation and major inconvenience. Pulled off to side of road to allow cool down. Delivered to mechanic for fluid change and checking and lubricating of calipers. This same thing happened 10 months later.
Tl*the contact owns a 2003 workhorse w20. While driving 40 MPH, the vehicle would not accelerate as fast as it normally would. In addition, the contact noticed a burning smelling coming from the rear of the vehicle. The mechanic stated that the calipers caused the failure and they replaced the left and right rear brake calipers. There is an open defect investigation for the service brakes: hydraulic (the federal safety agency action number ea07016). The failure mileage was 16,000 and current mileage was 17,000. Updated 02-06-08. *kb the consumer stated at the first observation the left rear caliper was extremely hot to the touch and all other calipers seemed to have normal temperature. Updated 02/06/08
Tl*the contact owns a 2003 damon workhorse (na). While driving 30 MPH, the contact was flagged down by another motorist and advised to pull over. Once he pulled off the road, he discovered that the brakes failed. He stopped the vehicle with the emergency brake. The vehicle was towed to his residence. When the wheels were removed from the vehicle, the brake shoes were fine, however, the left rear wheel overheated and caused the caliper to boil the brake fluid. He was informed that the calipers and brake rotors needed to be replaced. The current and failure mileages were 15,100. Updated 01/24/08 . *lj updated
Brake failure. Rear brakes overheated and boiled the brake fluid. Coach was towed to camping time rv in oakwood, ga. It has been there for over a month awaiting parts. Brake pedal went to the floor. Rear hubs too hot to touch and boiled the brake fluid.*jb updated 01/11/08. *lj the master cylinder was defective. Updated
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Questions about the 2003 Workhorse W20
Is the 2003 Workhorse W20 reliable?
Owners have filed 11 complaints about the 2003 Workhorse W20, 1.8 times a typical W20 model year.
What is the most common problem with the 2003 Workhorse W20?
Brakes, with 11 complaints, typically around 16,000 miles.
How many recalls does the 2003 Workhorse W20 have?
1 recall, covering service brakes, hydraulic.
Was there a recall on the 2003 Workhorse W20 brakes?
Yes, 1 recall: 09V110000. Check your VIN to see if your car still needs the free repair.
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