2001 Workhorse W22: ABS light or ABS activating

Filed Aug 9, 2010 · Brakes · FL

Tl*the contact owns a 2001 workhorse w22 chassis. The contact stated that the brakes malfunctioned and locked while he was driving which caused the ABS sensor to melt. The brakes were replaced twice but the failure continued to occur. The contact referenced recall 09v110000 and stated that when he called the manufacturer, he was told that repairs were not scheduled to be performed until october 2010. He was also told that if the problem occurred again, he should continue pumping the brake pedal to activate the braking system. The contact felt that it was a safety concern which could cause a fire or crash to occur. The current mileage was approximately 31,000. The failure mileage was unknown.

Filed Jun 17, 2010 · Brakes · 40,200 miles · NC · fire

Tl* the contact owns a 2002 fleetwood south wind rv with 2001 workhorse w22 chassis. While driving at 15 MPH, the contact noticed an unusual burning odor and the brakes were not operating as normal. The contact discovered the brake fluid was extremely low and was causing the brake failure. The manufacturer verified the vehicle was involved in the federal safety agency campaign id number: 09v110000 (service brakes, hydraulic) and that the vehicle would need to be inspected before recall repairs were performed. The contact was not comfortable with driving the vehicle to the dealer for fear of a possible failure or crash. The vehicle was not repaired. The failure and current mileages were 40, 200. Updated 07/29/10 *bf the consumer experienced brake failure due to faulty piston in the bosch calipers. The ABS light did not illuminate to indicated there was a burnt sensor. Updated 08/03/10

Filed Jun 14, 2010 · Brakes · AL

Letter from senator sessions on behalf of constituent re brake failures on his motorhome (dot/I#2010-1141)*tgw 2001 workhorse w22 chassis. The consumer stated the first time he lost braking he was descending a narrow twisting mountain road. The consumer was able to bring the rv to complete and safe stop using the hand brake and downshifting. The consumer discovered the front wheel was smoking and nearly caught on fire. The rv was towed the next day, to the nearest workhorse facility. The dealer replaced all the burned parts, which included the calipers, ABS sensors, pin kit, rotor, oil seals and pads. Workhorse was aware of the design problem in the brakes related to a type of plastic instead of steel component in the caliper pistons that expanded with heat which prevented the brake from releasing from the braking position. In january 2004, the consumer again lost braking ability, narrowly avoiding a rear end collision with an 18 wheeler by swerving into the emergency lane. Again, the rv was to towed the dealer. Upon inspection, they determined both rear calipers had stuck which caused overheating of the brake fluid to a gel. The consumer stated at least three times, the brakes have overheated due to stuck calipers requiring removal of the wheels and lubricating the caliper pins. It wasn't until july 2005, two years after the consumer experienced a near fatal accident due to brake failure, that workhorse sent him copy of a dealer bulletin 50401-c describing a defect involving brake caliper hanging in a partial apply position that can get extremely hot causing severe damage to brake parts. Workhorse has denied the consumer reimbursement twice. *jb updated 09/09/11.

Filed Oct 26, 2004 · Brakes · 19,335 miles · FL

We have a 2001 winnebago adventurer class a motorhome on a workhorse w22 chassis. I am writing regarding the ABS braking system. In august 2004, while driving, it felt like the rv was getting a flat tire. We pulled over and found no evidence of that. All the instrument lights and gauges were working properly and no warning lights. On continuing down the highway, I noticed that when I applied the brake, it would steer to the right quite noticeably, and there was also a smell of burning plastic. The mechanic replaced the left front caliper, the melted ABS sensor and the cracked rotor due to excessive heat. I called workhorse and they had no brake, sensor or rotor problems reported. We used our extended warranty. The total bill was $1,252.67. Warranty paid $356.68 and we paid $895.99. The rv had 19,335 miles. Since then we have read of a couple of people with similar brake sensor problems, and talked with a camper who had replaced the front brake pads three times in less than 20,000 miles on workhorse chassis. I am beginning to think that this is not an isolated incident and maybe there should be a recall. There was evidently some malfunction for the ABS light not to give us a warning when I checked the dashboard. We have bragged on the workhorse chassis to so many of our friends and have been really pleased with its performance up to this point. I would like to think that workhorse would check into the problem and reimburse us and the warranty co.

Filed Jul 13, 2004 · Brakes, Suspension · 16,367 miles · MS

We have a 2001 dutchstar class a motorhome, built on workhorse chassis number 28321. I am writing for a number of reasons. The first being that I am requesting information on possible recalls that include this unit. I understand that there are two campaigns for the 2001 workhorse chassis, the federal safety agency # 04v084000, having to do with service brakes, hydraulic and # 01v317000, having to do with suspension:rear:springs:leaf spring assembly:u-bolt, leaf spring to axle. I would like to know whether our unit is included and if so, why we were not notified. The second reason I am writing has to do with the ABS brake sensors on the front wheels. In october of 2003, we had to have the right brake sensor replaced after it had burned up with only 13,523 miles on the unit. On july 6, 2004, both front ABS brake sensors burned up and required replacing with only 16,367 miles. Luckily, we were traveling at a low speed as the lack of the sensors apparently caused both front brakes to lock up, which could have been extremely dangerous had we been traveling on the highway instead of a city street. While I realize that the unit is out of the 3 year warranty, this appears to be a manufacturers defect when the same units burn up within 3000 miles. I have also spoken to a friend that has a 2002 w22 chassis and she has had the same problem, causing her to replace both front sensors. These sensors should be designed to last a lot more than 16,000 miles and certainly more than 3,000 miles. I feel that workhorse should take responsibility and reimburse us for the cost ($365.35) of the replacement of both ABS brake sensors.