Brake fail.
2003 Workhorse W22 brakes complaints
Page 4 of 5: complaints 71 to 100 of 111, newest first, as owners wrote them.
26 may 2009 - while driving my 2004 national dolphin (workhorse w-22) motorhome from cocoa beach, fl toward my destination, home, I encountered a strong pull of the vehicle to the right. Stopping and making an inspection of the front wheels revealed the right hub was very hot and a smell of hot brakes. I carefully made my way to the next campground; there I was able to contact an rv repair service. With their mobile service they came to the campground and made an inspection. Their finding revealed that a caliper, brake pads and brake line had gotten very hot and was damaged. Their recommendation was the replacement of these parts plus the ABS sensor, and for safety, replace the same parts to the other front wheel. I was stranded at this campground while parts were ordered and shipped. 29 may 2009 - the rv service company made the repairs at the campground with their mobile service at a cost of $1147.40. *tr the consumer stated he received a december 2009 updated notice regarding the defective brakes which stated a final remedy had been determined. However, when he called workhorse custom chassis to get a current update, they didn't have one. Updated 03/08/10
Noticed during a recent tire change that 3 out of 4 rotors had radial cracks completely through the disk. One on each rotor and two on the right front. No cracks were noted on the right rear. These cracks are only on the outer disk. No other cracks were found with the exception of light surface cracks on all inner and outer rotors.
Tl*the contact owns a 2004 georgie boy cruise master with a 2003 workhorse w22. The contact noticed brake failure within the chassis. After stopping the vehicle repeatedly, the front calipers would drag and build up heat. The brake pedal seemed spongy and would extend all the way to the floor, barely stopping the vehicle. The contact received a recall notice for the federal safety agency campaign id number 09v110000, but only received recorded messages when he called the manufacturer. The current mileage was 15,449 and failure mileage was approximately 15,200.
Tl*the contact owns a 2003 workhorse w22. While driving between 45-50 MPH on normal road conditions, the brake pedal extended to the floor without resistance when pressure was applied. The brakes began to lock up without warning. The vehicle was driven with caution and parked for an extended period of time. The failure recurred on a separate occasion. The failure occurred whenever the vehicle was in operation. The vehicle has not been repaired. The federal safety agency campaign id number 09v110000 (service brakes, hydraulic) was referenced; however, the repair part was unavailable due to a massive back order. The technician stated that the part would be unavailable until fall of 2009. The VIN was unavailable. The failure mileage was 30,000 and the current mileage was unknown.
Tl*the contact owns a 2003 workhorse w22 chassis. While the vehicle was idling, the contact smelled a strong burning odor. When the brake pedal was depressed, he experienced reduced braking capability and the ABS warning indicator illuminated on the instrument panel. He took the vehicle to a local repair shop and had the ABS sensor replaced due to overheating. The contact received a recall notice for the federal safety agency campaign id number 09v110000 (service brakes, hydraulic) and immediately called the manufacturer. A representative stated that a corrective remedy had not been developed; therefore, they could not repair the vehicle. The failure still persists. The failure and current mileages were not applicable. Updated 5/28/09 *cn the consumer stated once he got on the highway, the smell seemed to dissipate, but when he came to a steep grade and applied the brakes the pedal went to the floor and the ABS light illuminated. The consumer was able to get the vehicle to the side of the road. Affter the rv sat for an 1/2 the smell went away, but the ABS light stayed on. Updated 05/29/09.
We own 2003 rv on a workhorse chassis. We just received from workhorse safety recall 50901c interim notice. In may 2008 our rear brakes locked up in ocala, fl while enroute to our home in ri. Severe overheating with brake burning smell, brakes dragging and the brakes became suddenly mushy when applied, we did not realize it was our brakes because our windows were closed. When the ABS light came on I immediately pulled over, discovered the rear hubs were very hot. We were towed to a wheel and brake facility near I 75 where it was determined there was extensive damage from the heat. Replaced were bearings in the differential, calipers, rotors. Pads. We have contacted the repair facility to mail us a complete list of repairs. We had 23 days left on a five yr. Extended warranty that paid over $1700 and we paid out of pocket over $2100 that was not covered by the insurance for some reason. This yr, april 2009, we again tried to drive the rv home from central fl and made it 20 miles up us27 when again we noticed the burning smell, pulled over, and this time the front hubs were very hot so we returned the rv to the campground and make plans to have the front brakes fixed when we return in the fall. We did not feel there was any hope for us until we got the recall notice the other day here in ri.
Tl*the contact owns a 2003 monaco coach lapalma motor home. While driving approximately 40 MPH, the contact smelled something overheating on his vehicle. He pulled the motor home over to inspect it, but found no failures. Two miles later, the brake pedal became mushy and extended to the floor. The vehicle veered to the right. The contact allowed the vehicle to cool down. He restarted the vehicle and drove to his destination. By this time, there was coolant leaking from the motor and oil leaking from the bearings. The mechanic stated that the wheel bearings may have been defective. It was discovered that the ABS sensors were welded and the front passenger side brake was defective. The mechanic replaced the passenger side brake calipers and all of the related hoses. The fluids, hub bearings, and ABS sensors were also replaced. The contact received a recall notice for the failures after the vehicle was repaired. The federal safety agency campaign id number was unavailable. The failure mileage was 25,000 and current mileage was 26,300. Updated 06/08/09 *bf the consumer stated the first time they stopped was to put stabil in the gas tank for the winter. About 2 miles later, they smelled an odor and stopped the coach. About 1 mile before reaching their destination, the brakes were pulling and there was not much pedal and the ABS light illuminated. The caliper, hose and wheel speed sensor were replaced. Updated 06/18/09.
Tl*- the contact owns a 2003 w22 workhorse chassis. While driving the chassis started to pull to the right and a lot noise was heard coming from the brakes when apply. The contact made an appointment with the dealership to diagnose the brakes. The dealership stated that the ABS system had malfunctioned due to the extreme heat from the brake calipers being applied to the rotors. The contact found a recall via the internet but his vehicle did not fall into the recall parameters. The vehicle is currently at the dealership awaiting repairs. The current mileage was 28,392 and failure mileage 28,382.
Tl*the contact owns a 2003 workhorse w22 trailer. While driving 50 MPH, the contact smelled a burning odor coming from the front end of the vehicle. The vehicle began to pull to the right when the brakes were applied. He pulled the vehicle over and noticed that the front brakes were very hot. The vehicle was taken to the dealer and they determined that the front brake calipers and seals failed. The vehicle was repaired. Four years later, while driving 50 MPH, the contact smelled a strong burning odor coming from the rear of the vehicle. He exited the vehicle to inspect the failure and noticed that the rear brakes were very hot. The contact is in the process of taking the vehicle to the dealer for inspection and notifying the manufacturer. The failure mileage was 13,548 and current mileage was 27,835. Updated 5/7/09 *cn updated 05/12/09.
Tl*the contact owns a 2004 fleetwood pace arrow recreational vehicle on a 2003 workhorse . The contact stated that the plastic front wheel bearings and the front disc brakes overheated. In addition, the dealer discovered that the rear brakes also failed. The vehicle has not yet been repaired. The failure mileage was 11,119 and current mileage is 12,536. Updated 04-23-09 *bf the consumer stated the front axle plastic oil cups, innre axle seals, rotors and brake pads were destroyed by heat. During an visual inspection, it was apparent that the rear brakes were not working due to lack of contact between the brake pads and rotors. The rv has not been reapired duee to an ongoing investigation by the consumer. Upated 05/01/09.
Abs light came on and I went to have the vehicle serviced. The service tech showed me the rotors and calipers. They were badly cracked and overheated. Cost $4700 to repair. Would not warranty them because the computer code said I was riding the brakes. "false". They installed a zerk fitting on the shaft to the bell crank without documenting it.
Tl*the contact owns a 2003 workhorse chassis w22. While driving approximately 25 MPH, the brake pedal extended to the floor when the brake pedal was depressed. The risk of a crash was increased. The contact is in the process of having the vehicle inspected to determine the cause of the failure. He filed a complaint with the manufacturer. The failure and current mileages were not applicable.
The brakes on my 2003 workhorse chassis overheat. They also shudder when going down a hill while braking.
Brake failure.
Tl*the contact owns a 2003 workhorse w22. While sporadically depressing the brake pedal, the vehicle failed to stop. Upon further inspection, the contact noticed that the brake fluid was bubbling due to excessive heat exposure. He took the vehicle to the dealer because three of the ABS wheel sensors burned off and two of the ABS seals failed. The technician replaced the brake calipers and the seals at more than $1,000. The manufacturer would not assist because there was no recall. The failure and current mileages were not applicable. Updated 03/27/09 *bf the consumer stated on 2 separate occasions, he had to pull over and wait for the brakes to cool off. The third time, the brakes seized. The caliper was replaced. Updated 04/01/09.
On 12/4/08 as we were traveling in our 2003 allegro bay motorhome in stop and go traffic near mobile, al we once again for no apparent reason, started to smell brakes burning. With 26,482 miles on our coach, this is our third brake failure event in less than four months. I pulled over as soon as possible and checked the temperature of all brake assemblies with my infrared thermometer which I now keep available. The brake caliper on the front driver's side measured approx. 450 degrees. I allowed the brakes to cool, then proceeded to the nearest workhorse repair facility (approx. 12 miles). They replaced both front calipers, brake lines, pads and fluid. At my request, they also checked and lubricated the rear calipers for a total cost of $1,005.80. The repair facility kept the old parts.
While traveling in our rv for no apparently reason, we suddenly began to smell burning brakes, then the steering began to shimmy and vibrate. When the brake was applied the vibration increased. I immediately pulled off at a safe area, unhooked my tow vehicle and went for assistance. All four rotors and brake pads were replaced at a cost of $2209.89. This is the first time we have experienced any problems with our brakes and it happened suddenly with no warning. The old parts were sent back as "core" parts by the repair facility. We are now aware of the federal safety agency ea07-016 involving bosch brake calipers overheating, causing the rotors to go bad and believe our workhorse chasis which does have this brand of calipers has experienced the same problem as was described in this bulletin. Upon completion of this repair, we proceeded on our trip. About 75 miles farther, we again smelled brakes burning. We pulled off the road as fast as we could and called our roadservice. The passenger side front brake was smoking. They sent out a mobile repair tech who removed the tire/wheel, removed the caliper and lubricated the caliper slide. The caliper seemed to be working normally, however, we are at a loss as to what actually caused our problem and are concerned that the cause has not been addressed and it will reoccur.
Brakes locking up and burning the rotors on a 2003 w22 motorhome chassis.
Tl*the contact owns a 2003 workhorse chassis w22. While driving approximately 35 MPH, the front brakes locked and the brake pedal extended completely to the floor. As a result, the brake unit began overheating and the vehicle began to smoke. The contact took the vehicle to the dealer, but they could not identify a solution or provide a remedy. As of august 6, 2008, the vehicle has not been properly repaired. The failure mileage was 16,000 and current mileage was 24,130.
Brakes failed completely on my 2003 southwind motorhome (workhorse chassis) with only 10.000 miles.
The first incident we were on our way to florida. I was driving the vehicle down a steep grade in tennessee. I applied the brakes harder than usual and felt a rumble in the vehicle. When I was able to pull off the highway safely, the rumble was gone. I proceeded to florida and parked my rv for 2 weeks and then moved to another rv park for the month of december without incident. On january 1, 2008 I moved the rv to another rv park about 35 miles away. While I was driving I had to apply the brakes harder than usual because of a signal light change. Shortly after that I smelled a hot smell and felt the rumble in the brakes while braking, as in the first incident. I pulled off the road at a service station to assess the problem and my rear brake was smoking. After examining the brake area I discovered that the brake was stuck in the on position. By this time I was only about a mile from the rv park so I freed up the brakes and let them cool before proceeding. The service person that repaired my brakes stated that the calipers were rusted to the point that they stuck when applied hard. While at the rv park, another rv pulled in with the same problem. He also had the same chassis as I have. So after returning home for the summer I went on to the rv.net site and read their forum regarding brake issues and was astounded as to the number of owners that had the same issue as I had. I have owned many rv's in my day and have never experienced this kind of issue. I believe that there is a safety issue regarding the manufacturer.
Tl*the contact owns a 2003 workhorse chassis w22. While driving approximately 10 MPH, the ABS warning light illuminated on the instrument control panel and the cruise control failed. The contact noticed that the calipers in the brake system overheated. The dealer stated that his VIN was not included in the federal safety agency campaign id number 04v084000 (service brakes, hydraulic). The contact would have to pay $3,000 to repair the vehicle. The manufacturer would not provide assistance because his year was excluded from the recall. The failure mileage was 20,000 and current mileage was 23,000. The problem would also lead to wheel lock-up updated 06/25/08
I have had calipers and pads replaced once before. And now my brakes are surging really bad.
2003 w22 workhorse chassis brake failure ABS system damaged due to over heating of rotors on all four wheels.
Front brakes have locked up twice on this workhorse w22 chassis. The first time they were patched under warranty. However, the calipers were not replaced and they failed again one year later. Workhorse refused to pay for the repair even though they know from their past experience that all the calipers they used over a period of years are bad. This is a safety hazard and had I not recognized the problem and stopped there could have been a major fire in the motorhome in which my wife and I were riding. Their failure to even acknowledge the problem, even though there is a current the federal safety agency investigation, seems almost criminal. Is someone going to have to die before they are forced to pay for their mistakes. Earlier in the life of this rv the rear brakes locked up and the pads did indeed catch on fire but I was able to stop and extinguish them before the vehicle was burned. I would like for workhorse to acknowledge their problem and repay me the $1,177.37 that I had to pay to fix their problem.
Tl*the contact owns a 2003 workhorse w22. The contact stated that when he applied the brakes, they would drag after being released. The failure occurred while driving 15 MPH. He also stated that the brakes would squeak and grind and became worn due to releasing improperly. Workhorse confirmed that the VIN was included in the federal safety agency campaign id number 04v084000 (service brakes, hydraulic); however, they would not repair the vehicle. The purchase date, engine size, and number of cylinders were unknown. The current mileage was 30,000 and failure mileage was 3,000.
Rapid (excessive) brake pad wear by 32,000 miles and mostly interstate driving. Evidence of dragging caliper as seen by the uneven outer pad wear on all four wheels. Overheating and surface cracking on rotors. Too frequent ABS sensor replacement. Inspection at authorized workhorse service center discovered rotors severely cracked through. Given type of driving and level of motor home owner experience, brake parts should be expected to wear evenly and last considerably longer then mileage posted above. Given number of internet based similar complaints, I believe root cause of malfunction of brake system was not identified and addressed. Calipers should have been replaced and weren't. Low mileage or lack of usage cannot be argued in this case , as workhorse contends is a major factor.
Vehicle had brake failure 3 times in 36k miles. Additionally, axle seals have been replaced 3 times due to excessive heat from brakes. Brakes and seals have all been replaced 3 times. Spoke to workhorse numerous times, was told there is no maintenance to do on brakes, just have them inspected twice a year, and have them replaced if sticking, even if it is every 10k miles @ $2,000 per repair.
Re: the federal safety agency action number : ea07016 : --- workhorse custom chassis recall number 50401-c, the federal safety agency recall nol 04v‑084 for the bosch zops brake problem was completed to my 2003 holiday rambler vacationer, model 36dbd motorhome. - while vacationing and with just 2000 miles +/- later my right rear brakes caliper locked-up, the smell of smoke came in the motorhome and then when I went to apply the brakes, they went all the way to the floor. Good thing I was able to pulled over onto the side of the hwy to avoid having an accident. After a while when they cooled down, I pumped the brakes and they seem to be working ok. I was able to slowly proceed to my campground. Took the motorhome to an authorize workhorse dealer and they replace the caliper ,pads, sensor and rotor. Workhorse did covered the expenses for this repairs. At 11,000 miles +/- later after the recall work was completed, the right front wheel speed sensor went bad and had to be replaced. Now 18,000 miles +/- later after the recall was completed, the left rear bosch caliper hung-up, overheated and I had to have the caliper, pads, sensor and rotor replaced. I then contacted workhorse custom chasis about reimbursing the expenses I incurred and they declined. - I'm very afraid that the reminder of the original bosch calipers could lock-up, fail and cause me to have an accident. All repair work was done at an authorize workhorse custom chassis shop. - per the VIN records the left wheel speed sensor was changed out at 42 miles on motorhome-- purchased motorhome from private owner - mileage at time of purchased: 13,700 - motorhome mfg date: 8/02 - workhorse custom chassis mfg. Date 6/02.
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