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2002 Workhorse W22

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

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When problems were reported

Mileage at the reported incident

43 reports with mileage · 24 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 62 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 2 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

1 crash reports6 fire reports0 injury reports

Service Brakes, Hydraulic complaints

62 reports
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30,500 miles · Oct 6, 2008
Service Brakes, HydraulicFire

TL*THE CONTACT OWNS A 2002 NEWMAR MOUNTAIN AIRE WITH A WORKHORSE CHASSIS. THE CONTACT STATED THAT THERE WERE BRAKE SEIZURES WITH HIS BRAKE CALIPERS. WHILE DRIVING 30 MPH, THE BRAKES LOCKED UP AND CAUSED THE VEHICLE TO PULL TO THE RIGHT. THE FAILURE MELTED THE ABS WIRING AND NEARLY STARTED A FIRE. THE CONTACT ALSO STATED THAT…

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TL*THE CONTACT OWNS A 2002 NEWMAR MOUNTAIN AIRE WITH A WORKHORSE CHASSIS. THE CONTACT STATED THAT THERE WERE BRAKE SEIZURES WITH HIS BRAKE CALIPERS. WHILE DRIVING 30 MPH, THE BRAKES LOCKED UP AND CAUSED THE VEHICLE TO PULL TO THE RIGHT. THE FAILURE MELTED THE ABS WIRING AND NEARLY STARTED A FIRE. THE CONTACT ALSO STATED THAT THERE WAS AN ONGOING ISSUE WITH THE MANUFACTURER REGARDING THE BRAKES. THE REPAIR CENTER STATED THAT THE REPAIR WOULD COST APPROXIMATELY $3,000. THE DEALER STATED THAT THE FAILURE WOULD RECUR EVEN IF THE REPAIR WAS MADE. THE CURRENT MILEAGE WAS APPROXIMATELY 31,000 AND FAILURE MILEAGE WAS APPROXIMATELY 30,500. UPDATED 11/19/08. *JB

NHTSA ODI #10244500

26,293 miles · Sep 1, 2008
Service Brakes, Hydraulic

1. RANDOM LOCK UP OF VEHICLE BRAKES 2. OCCURRED SEPTEMBER 2006 AND AGAIN IN AUGUST 2008. EXTREME VEHICLE VIBRATION AND LOSS OF STEERING. BRAKES SMOKE AND BECOME EXTREMELY HOT. 3. VEHICLE CHECKED BY LES SCHWAAB TIRE STORE AND AUTHORIZED GM REPAIR CENTER. CHARGED FOR INSPECTION. NEITHER SHOP COULD DIAGNOSE CAUSE OR REPAIR NE…

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1. RANDOM LOCK UP OF VEHICLE BRAKES 2. OCCURRED SEPTEMBER 2006 AND AGAIN IN AUGUST 2008. EXTREME VEHICLE VIBRATION AND LOSS OF STEERING. BRAKES SMOKE AND BECOME EXTREMELY HOT. 3. VEHICLE CHECKED BY LES SCHWAAB TIRE STORE AND AUTHORIZED GM REPAIR CENTER. CHARGED FOR INSPECTION. NEITHER SHOP COULD DIAGNOSE CAUSE OR REPAIR NEEDED. *TR

NHTSA ODI #10240549

33,000 miles · Aug 20, 2008
Service Brakes, Hydraulic

HAD BRAKE RECALL IN 2/06. BRAKES NEARLY FAILED 7/08 ON TRIP OUT WEST. ABS SENSOR BAD, FRONT BRAKE PADS BAD, AND LEFT FRONT CALIPER BAD. THIS CORRESPONDS TO TROUBLES OTHER DRIVERS HAVE HAD WITH THIS SYSTEM. *TR

NHTSA ODI #10239009

12,420 miles · May 23, 2008
Service Brakes, Hydraulic

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 S…

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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. *TR

NHTSA ODI #10228805

16,000 miles · Apr 3, 2008
Engine And Engine CoolingService Brakes, HydraulicSuspension

TL*THE CONTACT OWNS A 2002 WORKHORSE W22 TRAILER. WHEN THE CONTACT EXITED THE VEHICLE, HE SMELLED THE BRAKES AND WHEEL BEARINGS BURNING. THE CONTACT REMOVED THE WHEEL AND NOTICED OIL FROM THE WHEEL BEARING COVERING THE TIRE. THE VEHICLE WAS TAKEN TO THE DEALER AND REPAIRED. IN OCTOBER OF 2007, THE CONTACT SMELLED AN ODOR COM…

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TL*THE CONTACT OWNS A 2002 WORKHORSE W22 TRAILER. WHEN THE CONTACT EXITED THE VEHICLE, HE SMELLED THE BRAKES AND WHEEL BEARINGS BURNING. THE CONTACT REMOVED THE WHEEL AND NOTICED OIL FROM THE WHEEL BEARING COVERING THE TIRE. THE VEHICLE WAS TAKEN TO THE DEALER AND REPAIRED. IN OCTOBER OF 2007, THE CONTACT SMELLED AN ODOR COMING FROM THE REAR BRAKES. THE VEHICLE WAS TAKEN TO THE DEALER, BUT THEY COULD NOT DUPLICATE THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 16,000. UPDATED 04/22/08. *LJ THE CONSUMER WAS TOLD THE REAR BRAKES WOULD NOT BE REPLACED WITH UPGRADED BRAKES. THE CONSUMER STATED THE PROBLEM STILL EXISTS WITH THE BRAKES. THE CHECK ENGINE LIGHT ILLUMINATED. THE CRUISE CONTROL DID NOT COME. UPDATED

NHTSA ODI #10223219

20,000 miles · Apr 2, 2008
Service Brakes, Hydraulic

TL*- THE CONTACT OWNS A 2002 WORK HORSEMAN CHASSIS W22. ON SEVERAL OCCASIONS THE CHASSIS BRAKES OVERHEATED. WHEN THE BRAKES OVERHEATED HE WOULD PULL OVER UNTIL THEY COOLED DOWN. ON APRIL 10, 2006 THE CONTACT EXPERIENCE A TOTAL FAILURE OF THE BRAKES, HE WAS TRYING TO SLOW DOWN, AND THE BREAK PEDAL WHEN DOWN TO THE FLOOR. IT WAS…

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TL*- THE CONTACT OWNS A 2002 WORK HORSEMAN CHASSIS W22. ON SEVERAL OCCASIONS THE CHASSIS BRAKES OVERHEATED. WHEN THE BRAKES OVERHEATED HE WOULD PULL OVER UNTIL THEY COOLED DOWN. ON APRIL 10, 2006 THE CONTACT EXPERIENCE A TOTAL FAILURE OF THE BRAKES, HE WAS TRYING TO SLOW DOWN, AND THE BREAK PEDAL WHEN DOWN TO THE FLOOR. IT WAS FOUND THAT THE RIGHT FRONT CALIPER OVERHEATED. THE DEALER REPLACED THE TUBE, CALIPER, ABS SENSOR,. BREAK PADS, FLUIDS AND GUIDE PINS. THE SECOND MAJOR FAILURE OCCURRED MARCH 19, 2008 THE ABS LIGHT TURNED ON AND BRAKING POWER WAS LOST. AT WHICH TIME THE LEFT FRONT SIDE CALIPER WAS FOUND TO HAVE OVERHEATED. THE DEALER REPLACED THE CALIPER, FLUIDS, ABS SENSOR, AND BREAK HOSE, THIS REPAIR WAS COVER BY THE WARRANTY. THE CURRENT MILEAGE WAS 30,000, AND THE FAILURE MILEAGE WAS 20,000.

NHTSA ODI #10223192

11,000 miles · Jan 16, 2008
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING 60 MPH, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE BEGAN TO PULL BACK AND FORTH. THERE WERE NO WARNING INDICATORS PRIOR TO THE FAILURE. THE CONTACT PULLED OFF THE ROAD. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THEY STATED THAT THE BRAKE CALIPERS NEEDED TO BE REPLAC…

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TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING 60 MPH, THE BRAKE PEDAL WAS DEPRESSED AND THE VEHICLE BEGAN TO PULL BACK AND FORTH. THERE WERE NO WARNING INDICATORS PRIOR TO THE FAILURE. THE CONTACT PULLED OFF THE ROAD. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THEY STATED THAT THE BRAKE CALIPERS NEEDED TO BE REPLACED. THE CALIPERS AND ALL OTHER BRAKE COMPONENTS WERE REPLACED. THE VEHICLE WAS PREVIOUSLY SERVICED FOR NHTSA CAMPAIGN ID NUMBER 04V084000 (SERVICE BRAKES, HYDRAULIC). THE FAILURE MILEAGE WAS 11,000 AND CURRENT MILEAGE WAS 18,565. UPDATED 02-12-08 *BF THE CONSUMER STATED SAFETY RECALL 50401-C PERFORMED ON 09/24/04 AT 10,511 MILES. THE CONSUMER STATED MANUFACTURER SHOULD REIMBURSE HIM FOR THE COST OF REPAIRS IN THE AMOUNT OF $ 3,323.30. UPDATED 02/12/08 *TR

NHTSA ODI #10215122

48,450 miles · Jan 4, 2008
Service Brakes, Hydraulic

2002 HOLIDAY RAMBLER VACATIONER. REPLACED ENTIRE BRAKING SYSTEM ON 05/21/2005PERRECALL BULITEN #50401-C 32071 MILESON COACH ALL4ROTORS WERE CRACKED ON 11/02/2007 BRAKES MAKING NOISE NOW 3 ROTORS ARE CRACKED.WORKHORSE REFUSE TO REPLACE ROTORS PROBLEM DUE TO EXESSIVE HEAT BRAKES BEING APPLIED FOR 2 MINUETS REPAIRS HAVE NOT BEEN M…

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2002 HOLIDAY RAMBLER VACATIONER. REPLACED ENTIRE BRAKING SYSTEM ON 05/21/2005PERRECALL BULITEN #50401-C 32071 MILESON COACH ALL4ROTORS WERE CRACKED ON 11/02/2007 BRAKES MAKING NOISE NOW 3 ROTORS ARE CRACKED.WORKHORSE REFUSE TO REPLACE ROTORS PROBLEM DUE TO EXESSIVE HEAT BRAKES BEING APPLIED FOR 2 MINUETS REPAIRS HAVE NOT BEEN MADE YET . *CN

NHTSA ODI #10213700

48,583 miles · Jan 3, 2008
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING 50 MPH, HE HEARD A SCRAPING NOISE AND THE BRAKES THUMPED WHEN HE DEPRESSED THE BRAKE PEDAL. THE DEALER STATED THAT RIGHT FRONT AND BOTH REAR ROTORS WERE CRACKED. IN ADDITION, THEY FELT THAT THE CALIPERS OVERHEATED AND WAS THE CAUSE OF THE FAILURE. AS OF JANUARY 3, 2008,…

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TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING 50 MPH, HE HEARD A SCRAPING NOISE AND THE BRAKES THUMPED WHEN HE DEPRESSED THE BRAKE PEDAL. THE DEALER STATED THAT RIGHT FRONT AND BOTH REAR ROTORS WERE CRACKED. IN ADDITION, THEY FELT THAT THE CALIPERS OVERHEATED AND WAS THE CAUSE OF THE FAILURE. AS OF JANUARY 3, 2008, THE DEALER HAD NOT REPAIRED THE VEHICLE. THE CONTACT STATED THAT ALL FOUR ROTORS, CALIPERS AND HOSES WERE PREVIOUSLY REPLACED AS PART OF NHTSA CAMPAIGN ID # 04V084000 (SERVICE BRAKES: HYDRAULIC). THE MANUFACTURER REFUSED TO REPAIR THE FAILURE AGAIN. THE CURRENT AND FAILURE MILEAGES WERE 48,583. UPDATED 01/29/08 *LJ. UPDATED 01/29/08 *TR

NHTSA ODI #10213586

15,254 miles · Nov 15, 2007
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING 35 MPH, THE CONTACT NOTICED A BURNING SMELL COMING FROM THE FRONT PASSENGER SIDE OF THE VEHICLE. HE STATED THAT THE CALIPERS OVERHEATED. THERE WAS A RECALL REPAIR PERFORMED FOR THE SERVICE BRAKES, HYDRAULIC (NHTSA CAMPAIGN ID NUMBER 04V084000) IN FEBRUARY OF 2005. THE C…

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TL*THE CONTACT OWNS A 2002 WORKHORSE W22. WHILE DRIVING 35 MPH, THE CONTACT NOTICED A BURNING SMELL COMING FROM THE FRONT PASSENGER SIDE OF THE VEHICLE. HE STATED THAT THE CALIPERS OVERHEATED. THERE WAS A RECALL REPAIR PERFORMED FOR THE SERVICE BRAKES, HYDRAULIC (NHTSA CAMPAIGN ID NUMBER 04V084000) IN FEBRUARY OF 2005. THE CONTACT STATED THAT THE FIRST FAILURE DID NOT OCCUR UNTIL JUNE OF 2006. THE DEALER STATED THAT THE SLIDE RODS, CALIPERS, AND ROTORS SHOULD BE REPLACED. AS OF NOVEMBER 15, 2007, THE DEALER HAD NOT REPAIRED THE VEHICLE. THE FAILURE MILEAGE WAS 11,000 AND CURRENT MILEAGE WAS 15,300. UPDATED 01-14-08. *KB THE BRAKE SYSTEM WAS REPLACED. UPDATED 12/12/07

NHTSA ODI #10208992

Official recalls

2

09V110000 · Service Brakes, Hydraulic

Apr 3, 2009

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.

Consequence & remedy

Consequence: 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.

04V084000 · Service Brakes, Hydraulic

Feb 18, 2004

ON CERTAIN MOTORHOME CHASSIS EQUIPPED WITH BOSCH ZOPS, THE PADS CAN DRAG ON THE ROTOR SURFACE DUE TO THE PIN SLIDE.

Consequence & remedy

Consequence: 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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA07016 · Overheating Disc Brake Caliper

Opened Nov 16, 2007 · Closed Aug 19, 2009

Status: closed (inferred from source dates) · Service Brakes, Hydraulic

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.

Additional source detail variants (7)

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

EA03003 · Overheating Front And Rear Brakes

Opened Apr 9, 2003 · Closed Mar 3, 2004

Status: closed (inferred from source dates) · Service Brakes, Hydraulic:foundation Components

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.