NHTSA Complaint #10246982 — 2003 FLEETWOOD BOUNDER

BRAKE FAILURES(2) ON 2003 BOUNDER MOTORHOME WITH WORKHORSE W22 CHASSIS. CHASSIS PURCHASED NEW ON JAN.14,2004. LR BRAKE FAILED ON 8-29-08 ON I-5 AT OLYMPIA, WA, WITH APPROX. 21,100 MILES ON VEHICLE. RR BRAKE FAILED ON 9-29-08 ON HWY. 20 IN COUPEVILLE, WA AT APPROX.21,482 MILES. WEATHER WAS CLEAR AND ROADS WERE DRY; DUAL HOLDING TANKS WERE EMPTY; 100 GAL WATER TANK WAS ALSO EMPTY; FUEL TANK WAS ABOUT 1/2 FULL (35 GAL.). MOTORHOME WAS NOT OVERLOADED AND NO VEHICLE WAS IN TOW. 8-29 FAILURE OCCURRED WHILE SLOWING IN PRE-LABOR DAY WEEKEND TRAFFIC AND BRAKE PEDAL WENT TO THE FLOOR ON INITIAL APPLICATION. REPEATED APPLICATIONS OF BRAKE PEDAL GAVE ABOUT 1/2 PEDAL TRAVEL WITH GREATLY LESSENED DECELERATION TIME AND STOPPING DISTANCE . THE SECOND FAILURE ON 9-29-08 OF THE RIGHT REAR BRAKE ASSEMBLY WAS LESS SURPRISING AND BRAKE PEDAL PUMPING WAS MORE INSTINCTIVE. STOPPING A 24,000 POUND MOTORHOME ON AN EMERGENCY BRAKE THAT MERELY CLAMPS AROUND THE DRIVE SHAFT IS NOT A VIABLE OPTION. REPAIRS REQUIRED REPLACEMENT OF ALL AFFECTED BRAKE ROTORS, BOSCH CALIPERS, AND BRAKE PADS, PLUS A WHEEL SPEED SENSOR FOR THE ABS SYSTEM ON THE RIGHT REAR BRAKE FAILURE. APPROX. $2200 IN REPAIR COSTS FOR TWO BRAKES. A NEIGHBOR OF MINE WITH EXACT SAME YEAR AND MODEL MOTORHOME/CHASSIS AS MINE IS NOW AT A REPAIR FACILITY IN YUBA CITY, CA HAVING EXPERIENCED FAILURE OR BURN-OUT OF ALL 4 BRAKE ASSEMBLES WHILE ENROUTE FROM RENO,NV TO SACRAMENTO,CA.. I STRONGLY FEEL THAT THE SAFETY RECALL ON W-22 BRAKE SYSTEMS NEEDS TO BE EXTENDED BEYOND THE CHASSIS #33356806 CUTOFF SPECIFIED IN NHSTA RECALL 04V084000. THANK YOU FOR YOUR TIME AND CONSIDERATION IN THIS MATTER. *TR