The contact owns a 2002 Workhorse W22 Chassis. The contact stated that while driving at an undisclosed speed, the brake pedal went to the floorboard while depressed. Additionally, the ABS warning light was illuminated. The contact related the failure to the federal safety agency Campaign Number: 09V110000 (Service Brakes, Hydraulic). The vehicle was not diagnosed nor repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 21,000.
The worst 2002 Workhorse W22 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Brakes64
- Engine4
- Suspension2
- Acceleration1
- Electrical1
- Lights1
- Transmission1
- Visibility1
Specific symptoms reported on the 2002 Workhorse W22
Recalls 2
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
Service brakes, hydraulic
- 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
See all 2 recalls for the 2002 Workhorse W22
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
Overheating front and rear brakes
This investigation was derived from information gathered during pe02-046, bosch disc brake calipers.this investigation focused on the vehicle manufacturer, newmar.subject vehicles were those built with a hydraulic brake system incorporating the bosch zero offset pin slide (zops) calipers.odi'sconcern wasexcessive wheel end heat, possibly resulting in a wheel end fire.during the investigation, odi discovered two specific newmar vehicle models, those built on newmar chassis and those built on a workhorse chassis. As a result of the ageny's investigation into this matter, all newmarowners will be notified (04v‑019) and the remedy will be applied to their vehicles. Some newmar vehicles (1,795) built on the workhorse chassis are being recalled by workhorse (04v‑084).this investigation is closed.further details are provided on pages 2, 3, and 4.copies of both safety recalls are attached.
EA03003
What 2002 Workhorse W22 owners say
Most recent owner complaints, unedited.
We just purchased this motorhome and during my investigation for various repairs found there were 2 recalls on this coach. Only 1st of the 2 of the recalls was addressed with the 2nd recall being a more intense modification of the 1st. I am now trying to find out how to get the 2nd recall implemented since navistar absorbed workhorse and navistar has both changed their business model and is now seeking a buyer. Somehow, some way, the liability of insuring all repairs are completed rests with someone. Thanks for your help in giving me some direction to get this resolved. 😀 mark egan*dt
1) the manufacture, winnebago industries, equipped the driver "cockpit" of the vehicle with thermopane windows with an identified weakness. The seals in the windows are inadequate to maintain seal integrity, thus allowing air infiltration. Said air infiltration caused fogging of the glass, and an accumulation of condensation within the glass. The front "cockpit" windows on both sides became so fogged over and dirty in between the windows, the driver was unable to see out. This was a particular safety issue when passing. The driver cannot see into the passenger side mirror to safely pull back into the driving lane. Nor could the mirrors be used while driving or in reverse. The replacement of these small "cockpit" windows was to the tune of $500 per window. Also, replacement does not equal original manufacture so now the windows "whistle" with certain wind directions while driving. This is quite annoying to listen to while driving. Lg
Tl* the contact owns a 2002 workhorse w22. The contact stated that the ABS warning indicator flashed and remained illuminated. In addition, the brake pedal was depressed and traveled to the floorboard, creating the risk of a potential crash. The contact had to apply force to the brake pedal to stop the vehicle. The vehicle was not diagnosed or repaired. The vehicle was not included in the federal safety agency campaign numbers: 04v084000 (service brakes, hydraulic) and 09v110000 (service brakes, hydraulic); however, the vehicle exhibited the same failure listed in the recall campaigns. The manufacturer was notified. The failure mileage was not available. *bf consumer stated recall taking care of by workhorse.
2002 damon intruder on a 2002 workhorse w22 chassis. Consumer states defective calipers and seeks reimbursement for repairs *tgw the consumer stated the rotors, seals, pads and hoses also had to be replaced. The consumer believed the defective calipers caused damage to the other brake components.
Non-availability of parts, the federal safety agency recall # ea02035. I have tried to make an appt w/an authorized workhorse chassis service center. The two centers nearest me have had the caliper kits on order for the longest time. I feel that workhorse custom chassis is dragging their feet when supplying the service centers.
2002 workhorse w22 chassis. Consumer writes in regards to problems with workhorse brakes and requests reimbursement *tgw the consumer stated the first problem he encountered with the rv was the smell of burning brakes which was noticed in 2004 and the repairs were done during the bosch brake caliper recall. The next problem came in late 2007 when the consumer started experiencing brake failure and the ABS light illuminated. The calipers, rotors and ABS repairs were completed at a cost of $3700. The extended warranty covered roughly half the cost, but the consumer had to pay over $1800. The denial letter workhorse sent the consumer, stated the work that was performed in 2004 showed no issues in regards to workmanship or material defects
2002 workhorse w22 chassis. Consumer is seeking reimbursement for a towing bill due to problems with workhorse custom chassis *tgw the consumer stated the brakes failed to release while driving.
2003 pace arrow motorhome on a 2002 workhorse w22 chassis. Consumer is requesting reimbursement for brake caliper replacement since this was a recall issue for workhorse w22 chassis. *kb the consumer stated after the rv was purchased, the ABS light illuminated and the brake pedal was soft. Brake fluid leaked out and the wheel grease was extremely hot. The brake line also had to be replaced.
Tl*the contact owns a 2002 bounder 36u rv equipped with a workhorse chassis w22. The vehicle was taken to the dealer and repaired under the federal safety agency campaign id number 09v110000 (service brakes, hydraulic). The technician informed that the front and rear rotors had severe cracks so both rotors were replaced at the expense of the owner. The contact stated that the recall remedy should include the replacement of the rotors. The failure mileage was 40,126. Updated 01/24/11
Compare the 2002 Workhorse W22
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Questions about the 2002 Workhorse W22
Is the 2002 Workhorse W22 reliable?
Owners have filed 67 complaints about the 2002 Workhorse W22, 6.7 times a typical W22 model year. It is one of the years we flag to avoid.
What is the 2002 Workhorse W22 year score?
The 2002 Workhorse W22 scores 5 out of 100 (poor). The score compares it with the other model years of the Workhorse W22: 75 is a typical year, 50 means twice the usual complaints, and serious complaints and recalls lower it.
What is the most common problem with the 2002 Workhorse W22?
Brakes, with 64 complaints, typically around 30,000 miles. Next is engine (4).
How many recalls does the 2002 Workhorse W22 have?
2 recalls, covering service brakes, hydraulic.
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