NHTSA Complaint #10209084 — 2004 ITASCA SUNCRUISER

THE VEHICLE IN QUESTION IS A 2004 ITASCA SUNCRUISER 35 FOOT MOTORHOME BUILT ON A WORKHORSE W22 CHASSIS. IT WAS PURCHASED ON JUNE 30, 2004. IT WAS PURCHASED NEW WITH 1911 MILES ON THE ODOMETER AND HAD 11391 MILES AT THE TIME OF THE INCIDENT. ON SEP 6, 2007 WHILE TRAVELING FROM THE EAST COAST OF FLORIDA TO KISSIMMEE, FL, I NOTICED THE RV PULLING TO THE LEFT WHEN BRAKING AS WE APPROACHED KISSIMMEE. WHEN WE PULLED INTO THE CAMPGROUND, I SMELLED ?HOT? FLUID AND NOTED LIQUID DRIPPING FROM THE RIGHT FRONT WHEEL ONTO THE TIRE. THE WHEEL COVER WAS VERY HOT. WHILE MOVING TO OUR CAMPSITE, THE BRAKES WERE VERY SPONGY, ALTHOUGH THEY DID STOP THE VEHICLE. I CALLED THE WORKHORSE CUSTOMER ASSISTANCE CENTER AND WAS REFERRED TO AN AUTHORIZED DEALER IN THE AREA. I CALLED THEM AND WAS ABLE TO MAKE AN APPOINTMENT THE NEXT MORNING. THEY WERE ABLE TO EXAM THE VEHICLE IMMEDIATELY AND FOUND BOTH RIGHT SIDE ROTORS SCORED, WITH EVIDENCE THAT THE BRAKE CALIPERS HAD SEIZED. THE FLUID ON THE RIGHT FRONT WHEEL WAS DISCOVERED TO BE GEAR OIL, MOST LIKELY FROM THE HUB OVERHEATING. THE AUTHORIZED DEALER PROCEEDED TO REFACE THE RIGHT SIDE ROTORS AND REPLACE THE BRAKE CALIPERS WITH THE ONLY TWO NEW CALIPERS HE HAD AVAILABLE. BRAKE PADS AND OTHER SEALS, GASKETS, ETC WERE REPLACED AS REQUIRED. THE DEALER SUGGESTED THAT I SHOULD HAVE THE TWO LEFT SIDE CALIPERS REPLACED ALSO, AS THEY WOULD PROBABLY FAIL SHORTLY. UNFORTUNATELY, PARTS TO ACCOMPLISH THIS WERE ON BACKORDER. HE ALSO INDICATED THERE WASN'T ANYTHING I COULD DO TO PREVENT FAILURE, OTHER THAN WATCHING THEM TO MAKE SURE THAT THE ROTORS ARE NOT DESTROYED IF AND WHEN THE CALIPERS DO SEIZE. UPON RETURNING HOME AND DOING SOME RESEARCH ON THE INTERNET, I DISCOVERED THAT WORKHORSE HAS A HISTORY OF PROBLEMS WITH BRAKE CALIPERS. THIS GOES ALONG WITH THE MECHANIC AT THE DEALER, WHO INDICATED THAT THEY HAVE TO CHANGE THEM ALL THE TIME. HE SHOWED ME A LARGE PILE OF CALIPER CASTINGS WAITING TO BE RETURNED FOR CORE CREDIT. *TR