NHTSA Complaint #10440813 — 2003 WORKHORSE W22

2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED. *JB