2001 WORKHORSE W22 — Problems, Recalls & Safety Data

TL* THE CONTACT OWNS A 2001 MONACO MONARCH EQUIPPED WITH A WORKHORSE W22 CHASSIS. THE CONTACT WAS DRIVING APPROXIMATELY 58 MPH AND APPLIED THE BRAKES, WHICH BEGAN TO PULSATE ABNORMALLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE FRONT BRAKE PADS, CALIPERS AND BOTH FRONT ROTORS WERE REPLACED. THE REPAIRS WERE MADE THREE SEPARATE TIMES. THE FAILURE PERSISTED AFTER EACH REPAIR WAS PERFORMED. THE CONTACT PLANNED TO REPLACE THE PASSENGER'S SIDE ROTOR HIMSELF. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 5,000.

TL*THE CONTACT OWNS A 2001 WORKHORSE W22 CHASSIS. THE CONTACT STATED THAT THE BRAKES MALFUNCTIONED AND LOCKED WHILE HE WAS DRIVING WHICH CAUSED THE ABS SENSOR TO MELT. THE BRAKES WERE REPLACED TWICE BUT THE FAILURE CONTINUED TO OCCUR. THE CONTACT REFERENCED RECALL 09V110000 AND STATED THAT WHEN HE CALLED THE MANUFACTURER, HE WAS TOLD THAT REPAIRS WERE NOT SCHEDULED TO BE PERFORMED UNTIL OCTOBER 2010. HE WAS ALSO TOLD THAT IF THE PROBLEM OCCURRED AGAIN, HE SHOULD CONTINUE PUMPING THE BRAKE PEDAL TO ACTIVATE THE BRAKING SYSTEM. THE CONTACT FELT THAT IT WAS A SAFETY CONCERN WHICH COULD CAUSE A FIRE OR CRASH TO OCCUR. THE CURRENT MILEAGE WAS APPROXIMATELY 31,000. THE FAILURE MILEAGE WAS UNKNOWN.

TL* THE CONTACT OWNS A 2002 FLEETWOOD SOUTH WIND RV WITH 2001 WORKHORSE W22 CHASSIS. WHILE DRIVING AT 15 MPH, THE CONTACT NOTICED AN UNUSUAL BURNING ODOR AND THE BRAKES WERE NOT OPERATING AS NORMAL. THE CONTACT DISCOVERED THE BRAKE FLUID WAS EXTREMELY LOW AND WAS CAUSING THE BRAKE FAILURE. THE MANUFACTURER VERIFIED THE VEHICLE WAS INVOLVED IN NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC) AND THAT THE VEHICLE WOULD NEED TO BE INSPECTED BEFORE RECALL REPAIRS WERE PERFORMED. THE CONTACT WAS NOT COMFORTABLE WITH DRIVING THE VEHICLE TO THE DEALER FOR FEAR OF A POSSIBLE FAILURE OR CRASH. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 40, 200. UPDATED 07/29/10 *BF THE CONSUMER EXPERIENCED BRAKE FAILURE DUE TO FAULTY PISTON IN THE BOSCH CALIPERS. THE ABS LIGHT DID NOT ILLUMINATE TO INDICATED THERE WAS A BURNT SENSOR. UPDATED 08/03/10*JB

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

TL*THE CONTACT OWNS A 2001 WORKHORSE W22. WHILE DRIVING 30 MPH WHEN HE TRIED TO STOP AT A RED LIGHT HIS BRAKES DID NOT WORK. THE CONTACT CONTINUED TO APPLY PRESSURE TO THE BRAKES AND THE VEHICLE STILL WOULDN'T SLOW DOWN. HE PULLED INTO A STORE PARKING LOT WERE HE FINALLY GOT THE VEHICLE TO STOP. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 27,000 AND THE CURRENT MILEAGE WAS 28,000.