NHTSA Complaint #10335953 — 2001 WORKHORSE W22

LETTER FROM SENATOR SESSIONS ON BEHALF OF CONSTITUENT RE BRAKE FAILURES ON HIS MOTORHOME (DOT/I#2010-1141)*TGW 2001 WORKHORSE W22 CHASSIS. THE CONSUMER STATED THE FIRST TIME HE LOST BRAKING HE WAS DESCENDING A NARROW TWISTING MOUNTAIN ROAD. THE CONSUMER WAS ABLE TO BRING THE RV TO COMPLETE AND SAFE STOP USING THE HAND BRAKE AND DOWNSHIFTING. THE CONSUMER DISCOVERED THE FRONT WHEEL WAS SMOKING AND NEARLY CAUGHT ON FIRE. THE RV WAS TOWED THE NEXT DAY, TO THE NEAREST WORKHORSE FACILITY. THE DEALER REPLACED ALL THE BURNED PARTS, WHICH INCLUDED THE CALIPERS, ABS SENSORS, PIN KIT, ROTOR, OIL SEALS AND PADS. WORKHORSE WAS AWARE OF THE DESIGN PROBLEM IN THE BRAKES RELATED TO A TYPE OF PLASTIC INSTEAD OF STEEL COMPONENT IN THE CALIPER PISTONS THAT EXPANDED WITH HEAT WHICH PREVENTED THE BRAKE FROM RELEASING FROM THE BRAKING POSITION. IN JANUARY 2004, THE CONSUMER AGAIN LOST BRAKING ABILITY, NARROWLY AVOIDING A REAR END COLLISION WITH AN 18 WHEELER BY SWERVING INTO THE EMERGENCY LANE. AGAIN, THE RV WAS TO TOWED THE DEALER. UPON INSPECTION, THEY DETERMINED BOTH REAR CALIPERS HAD STUCK WHICH CAUSED OVERHEATING OF THE BRAKE FLUID TO A GEL. THE CONSUMER STATED AT LEAST THREE TIMES, THE BRAKES HAVE OVERHEATED DUE TO STUCK CALIPERS REQUIRING REMOVAL OF THE WHEELS AND LUBRICATING THE CALIPER PINS. IT WASN'T UNTIL JULY 2005, TWO YEARS AFTER THE CONSUMER EXPERIENCED A NEAR FATAL ACCIDENT DUE TO BRAKE FAILURE, THAT WORKHORSE SENT HIM COPY OF A DEALER BULLETIN 50401-C DESCRIBING A DEFECT INVOLVING BRAKE CALIPER HANGING IN A PARTIAL APPLY POSITION THAT CAN GET EXTREMELY HOT CAUSING SEVERE DAMAGE TO BRAKE PARTS. WORKHORSE HAS DENIED THE CONSUMER REIMBURSEMENT TWICE. *JB UPDATED 09/09/11. *JB