NHTSA Complaint #10280097 — 2004 GULF STREAM SUN VOYAGER

ON 7/15/2009 AFTER LEAVING LIMA, MT ON OUR WAY TO BASIN MT, I NOTICED BRAKES SEEMED TO BE GRABBING, SO MADE SURE TO DOWNSHIFT ON ALL HILLS. AS WE PULLED INTO CAMPGROUND AT BASIN, HEARD METAL TO METAL ON BRAKES. ASSUMING NEW BRAKE PADS NEEDED, ORDERED THEM FROM NEAREST WORKHORSE DEALER IN GREAT FALLS, MT, DROVE 130 MILES; PAID FOR THEM AND RETURNED. PULLED FRONT LEFT WHEEL & DISCOVERED ROTOR WAS CRACKED ON OUTBOARD ROTOR SURFACE. PULLED FRONT RIGHT WHEEL AND FOUND ROTOR CRACKED IN TWO PLACES ON OUTSIDE SURFACE. CALLED WORKHORSE DEALER IN GREAT FALLS AND WAS TOLD TO TAKE PICTURES OF ALL FOUR ROTORS, E-MAIL TO THEM AND THEY WOULD SEND ON TO WORKHORSE. LOOKED UP RECALL 50901-C ON INTERNET RECALLING ALL MODELS W22 SERIES RV CHASSIS, 7/24/2000 THROUGH 12/19/2007. AFTER WORKHORSE (CHRIS EGAN) HEADQUARTERS REC'D PICTURES, SAID WE HAD TO TAKE TO GF AND HAVE DEALER TAKE THE SAME PICTURES. WE DID THAT. THEN WORKHORSE SAID WILL NOT COVER COSTS. THEIR RECALL IS ON A PISTON STICKING AND OVERHEATING. OUR COMPLAINT IS THE CALIPERS STICKING IN THE RAILS AND DRAGGING ON THE OUTBOARD SIDE OF ROTORS. IF IT HAPPENS ON ALL FOUR WHEELS (REAR ROTORS HAD THREE AND FOUR CRACKS ON OUTBOARD SIDES) IT IS A MANUFACTURING DEFECT, AND SHOULD ALSO BE RECALLED. I AM A RETIRED MASTER MECHANIC AND HAVE NEVER SEEN ALL FOUR ROTORS CRACKED ON ANY VEHICLE. WHEN I ROTATED THE TIRES APRIL 2009 IN YUMA AZ, SAW NO CRACKS IN FRONT ROTORS; CHECKED BRAKE FLUID AND IT WAS NOT LOW. AT 3907 MILES LATER, (TRIP ODOMETER) ALL FOUR ROTORS WERE FOUND CRACKED ON OUTBOARD SIDE AND LEFT FRONT BRAKE WORN DOWN TO METAL ON THE PAD AND SCRAPING ON OUTBOARD SIDE OF ROTOR. THIS IS A DIFFERENT AND DANGEROUS PROBLEM NOT COVERED BY THE RECALL. *TR