2002 Workhorse W22: brake failure

Filed Mar 23, 2023 · Brakes · 21,000 miles · CA

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.

Filed Jan 21, 2011 · Brakes · CA

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

Filed Jan 20, 2011 · Brakes · IL

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.

Filed Oct 19, 2010 · Brakes · 40,000 miles · ID

Tl*the contact owns a 2003 national dolphin motor home with a 2002 w22 workhorse chassis. The vehicle was taken to a local mechanic when the brakes failed. The brake rotors, brake pads and the seals were repaired at the contacts expense. He received a recall notice on the calipers from workhorse but the brake rotors, brake pads and the seals have failed again. The dealer stated that the would only repair the calipers but not the brake system; therefore, the contact would be responsible for the repairs. The dealer contacted workhorse was waiting for a response before they proceed. The manufacturer was not notified. The failure mileage was 40,000. Updated 01/12/11*lj the dealer informed the consumer the rotors were cracked. Updated 04/06/11

Filed Oct 13, 2010 · Brakes · FL

2002 workhorse w22 chassis. Consumer writes regarding brake failure *tgw the consumer stated he experienced brake failure in december 2004. The brakes were temporarily repaired, because according to the repair shop a recall was issued, however, the recall parts were not available. In december 2009 the consumer received a recall notice regarding the brakes. However, when he went to the dealer he was informed again the parts were not available. In july 2010, he experienced another brake failure. The consumer was then informed the parts wouldn't be available until december 2010. So therefore, another temporary brake repair was performed. The consumer stated while driving, he realized he had no brakes and had to pump them twice in order to stop. The ABS light illuminated as well. The calipers and sensors needed to be replaced, the wheel seal was leaking, the rotors were destroyed and the calipers boots had melted.

Filed Dec 8, 2009 · Brakes · 8,406 miles · FL

Tl* the contact owns a 2002 workhorse w22. The brake pedal would not release after application. Also the brake system would intermittently over-heat. The vehicle was taken to an authorized dealer, and a spring on the brake pedal as installed. The repair did not remedy the failure. The caliper guide pin kit and guide pin boot kin were replaced. In 2006, while driving down the highway, he attempted to use the brakes and they were unresponsive. He allowed the vehicle to naturally decelerate. He went to another authorized dealer, and the front wheel seal, rear wheel seal, two calipers, two brake pad kits, an axle gasket, and two ABS wheel sensors were replaced under warranty. Also, grease zeroed also installed on the jack valve at another dealer under warranty . In 2008, while driving the brake failed again. He shifted a vehicle into a lower gear and used the emergency brake to stop. He then received a recall notice in april of 2009 (recall 09v110000) but received no remedy. He spoke with two representatives in december 2009,who told him that they had no way of knowing how to repair the issue. The current mileage was approximately 34,750. The failure mileage was 8,406.

Filed Oct 5, 2009 · Brakes · 35,000 miles · 00 · crash

Incident in england: soft pedal & loss of braking, on imported american motorhome (rv). There are thousands of imported rvs here. My vehicle is a 2002 'trail lite 262' by r-vision on a workhorse chassis. It is used regularly & has 35,000 miles. A recent service noted the brake calipers were free to move, but suitable lubricant was applied as a precaution. Two weeks ago, approaching a sharp double bend at 40 to 50 MPH, the brake pedal went to the floor with no retarding action. I could not take the curve at that speed, and quickly put the auto gearbox into low, and steered off the road onto the grass, then a farm entrance. I was lucky - elsewhere that road has a drainage ditch alongside. It could have been serious. After stopping I realized there was a very strong burning smell from both rear brakes. I crawled along for half a mile and parked up. Next morning the pedal feel had returned; it was obvious that overheating had boiled the fluid causing pressure loss. I phoned the specialist rv garage which services it. They told me in recent weeks they had 4 vehicles with the same fault, and replaced brake calipers in which the pistons were seizing or hanging. All were on the workhorse chassis, around 2002 -3 with similar usage and mileage. I am convinced this is a serious manufacturing defect affecting rvs in the uk. I note on your website workhorse have accepted this fault, stating that it affects the w22 chassis etc. The service mechanic here assures me the very same brakes are also fitted to the p22 chassis (which mine is). In the uk there has been no recall campaign or publicity about the fault. I am concerned there could be a serious accident, or even fatality. May I suggest you communicate the problem to our 'vehicle operating & safety agency' so they issue a warning or recall. Also, can you advise me how to get the faulty brakes replaced by workhorse please.

Filed Jul 8, 2009 · Brakes · 32,870 miles · FL

Tl*the contact owns a 2002 workhorse w22 motor home. The contact stated that the brakes failed during stop-and-go traffic. He also stated that the brakes were dragging. The brake pedal extended to the floor when it was depressed. The manufacturer stated that they would assist with the repairs and that the vehicle was included in the federal safety agency campaign id number 09v11000. The dealer stated that they needed approval directly from the manufacturer before making any repairs. The manufacturer could not be reached. The mileages were unknown. Updated 8/10/09 *cn updated 08/13/09.

Filed May 26, 2009 · Brakes, Electrical · 20,000 miles · PA

Tl*the contact owns a 2002 winnebago adventurer rv, model 35u. The contact received a recall notice regarding the braking system on the vehicle. In october of 2008, the brakes failed and nearly caused a crash. The contact called the dealer and a lawyer and was advised to file a complaint with the attorney general in pennsylvania. The attorney general referred the contact to the attorney general in ohio. The dealer refused to repair the vehicle. The vehicle has been parked at a storage facility since october 10, 2008 and had to be towed. The cost to repair the vehicle was estimated between $3,000 and $5,000. Prior to the failure, the dealer charged $795 for a system check. While driving approximately 40 MPH down a hill, the vehicle failed and was towed away. The contact called the manufacturer, but there was no answer. The dealer was notified of the near crash and hung up the phone on the contact. The federal safety agency campaign id number was unknown. The current mileage was 20,000. The consumer also had electrical problems with the rv. Updated 06/16/09.

Filed Oct 20, 2008 · Brakes · 40,000 miles · FL

Tl*the contact owns a 2002 workhorse w22. While driving approximately 10 MPH in a residential community, the brake pedal extended to the floor. The vehicle failed to stop and coasted the rest of the way to its destination. The vehicle was towed to a dealer. The current and failure mileages were 40,000. Updated 11/07/08 *bf the front brakes locked up and the pedal went to the floor. The ABS light illuminated. The calipers locked up and damaged the flex hose and ABS sensor. Updated 11/13/08.

Filed Oct 8, 2008 · Brakes · 40,856 miles · TX

Tl*the contact owns a 2002 workhorse w22 . While driving between 20-30 MPH, the brakes failed. The brake pedal extended to the floor when it was depressed. The contact pulled off the road into a grassy area, which slowed down the vehicle and eventually LED to a complete stop. He pulled the vehicle back onto the road and drove to a shopping center. The brakes were performing better, but displayed very little stopping power. The vehicle was towed to a dealer and they stated that the passenger side caliper had been locked up for quite a while. The dealer replaced the bearing seal on the front passenger side wheel, brake pads, front and rear rotors, and the front and rear calipers. After the repairs were made, the contact discovered an investigation relating to the service brakes, hydraulic, which described the same failures he was experiencing. The federal safety agency campaign id number was unknown. The failure mileage was 40,856 and current mileage was 43,926. Updated 11/7/08 *cn the calipers locked up, which caused the rotors to warp. Updated 11/13/08.

Filed May 23, 2008 · Brakes · 12,420 miles · NC

Coming home from camping,in traffic when ABS light comes on. There's a smell of burning brakes. Rv seems to be under a heavy load. After a few stops braking gets harder. By the time I make it home almost a complete brake failure. Brake pedal goes to the floor. Pumping the brakes maintain some stopping control. Parked rv and seeking help.