NHTSA Complaint #10243450 — 2004 WORKHORSE W20

ON 9/6/07, THE L.F. BRAKE ON MY MOTORHOME SEIZED UP AND OVERHEATED THE BRAKE ROTOR FOR ALMOST 10 MILES UNTIL I NOTICED SEVERE SHAKING IN THE STEERING WHEEL & SMELLED "BURNT BRAKE LINING" WHEN I STOPPED. I WAS DRIVING IN NORMAL CITY TRAFFIC NEAR ALLIANCE, OHIO; -NOT EXCESSIVE STOP AND GO, BUT THERE WAS MAYBE 4 RED LIGHTS OVER THE COURSE OF 3 MILES DISTANCE (AT 30 MPH) TO STOP. MY STOPPING WAS "NORMAL", NOT SUDDEN OR ERRATIC. THE LEFT FRONT HUB & WHEEL GOT SO HOT FROM THE CALIPER/BRAKE ASSY. SEIZING THAT IT BOILED AWAY ALL OF THE 90W LUBE ON THE WHEEL BEARINGS AND BLEW OUT THE RUBBER PLUG ON THE LUBE SIGHT GLASS. I LET IT COOL DOWN FOR AN HOUR, THEN LOOKED AT THE INNER SIDE OF THE L.F. WHEEL TO SEE IF I'D HAVE TO LOOSEN/PRY AWAY THE SEIZED BRAKE PAD OR CALIPER ASSEMBLY. SURPRISE, THE BRAKE PADS WERE ALREADY SITTING BACK AWAY FROM THE ROTOR; -THE CALIPER HAD APPARENTLY RETRACTED BY ITSELF AFTER COOLING DOWN. I PROCEEDED SLOWLY TO THE CAMPGROUND, 5 MILES AWAY, AND MADE ARRANGEMENTS TO GET SOME 90W LUBE OIL. LUBE WAS REPLACED THE NEXT DAY AND THE WHEEL BEARINGS STILL FELT GOOD; ANOTHER SIGHT CAP SEAL WAS INSTALLED. ON 9/12/07, I TOOK THE COACH TO MAINLINE TRUCK & TRAILER (A WORKHORSE CHASSIS SERVICE DEALER) IN SOLON, OHIO, FOR SERVICE. IN A NUTSHELL, I ENDED UP PAYING $828.28 TO REPAIR THE DAMAGE AND SERVICE MY COACH FOR FUTURE "PEACE OF MIND". THE FOLLOWING WORK WAS PERFORMED: SERVICED ALL CALIPER SLIDE PINS, LUBE, & BOOTS ON ALL 4 WHEELS; CONFIRM CORRECT CALIPER OPERATION ON ALL 4; REPLACE ABS WHEEL SENSOR ON LEFT FRONT; RESET ABS WARNING LIGHT; INSPECT ALL 4 ROTORS FOR CRACKS; REPLACE LF WHEEL BEARING INNER SEAL; INSPECT LF BEARINGS; INSPECT REAR AXLE HUB SEALS; ETC. ON 9/18/08, AT 11,891 MILES, MY RIGHT FRONT BRAKE SEIZED UP UNEXPECTEDLY! THIS TIME ALONG A 45 MPH STATE HWY WITH VERY INFREQUENT BRAKING. I BELIEVE THE PROBLEM HERE IS FAULTY ABS CONTROLLER AND OR THE BOSCH BRAKES. THEY DO NOT ALWAYS RELEASE THE CALIPERS. WORKHORSE IGNORES THIS PROBLEM! *TR