WORKHORSE Complaints

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 2003 WINNEBAGO BRAVE WITH A WORKHORSE W22 CHASSIS MOTOR HOME. WHILE DRIVING AT APPROXIMATE SPEEDS OF 55-60 MPH, THE CONTACT APPLIED THE BRAKES BUT THEY WOULD NOT ENGAGE. HE STATED HE PULLED OVER AND ALLOWED THE VEHICLE TO COOL OFF BEFORE PROCEEDING. THE CONTACT HAD PREVIOUSLY INQUIRED WITH THE MANUFACTURER ABOUT NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC) BUT HE WAS TOLD THAT THE PARTS NEEDED TO MAKE REPAIRS WERE NOT AVAILABLE. THE FAILURE AND CURRENT MILEAGES WERE 24,000.

TL*THE CONTACT OWNS A 2002 FLEETWOOD PACE ARROW RV. THE VEHICLE WAS EQUIPPED WITH A WORKHORSE CHASSIS W22. WHILE THE CONTACT WAS DRIVING APPROXIMATELY BETWEEN 50-50 MPH, PRESSURE WAS APPLIED TO THE BRAKES WITH A DELAY RESPONSE. THE VEHICLE WAS ABLE TO CONTINUE IN OPERATION. THE FAILURE OCCURRED INTERMITTENT. THE CONTACT RECEIVED A RECALL NOTIFICATION REGARDING THE HYDRAULIC BRAKES. THE NHTSA CAMPAIGN ID NUMBER WAS 04V084000. THE MANUFACTURER HAD NOT PROVIDED A REMEDY FOR THE RECALL DEFECT AT THE TIME OF THE COMPLAINT. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED FOR THE BRAKE MALFUNCTION. THE CONTACT HAD CONCERN OF THE SAFETY ISSUE INVOLVED. THE FAILURE MILEAGE WAS 23,358. UPDATED 07/29/10 *BF UPDATED 07/30/10*JB

TL*THE CONTACT OWNS 2003 DAMON INTRUDER RV. THE VEHICLE WAS EQUIPPED WITH A WORKHORSE CHASSIS W22. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 5 MPH, BACKING INTO A PARKING SPACE, THE BRAKES FAILED WITHOUT WARNING. THE EMERGENCY BRAKES WERE ENGAGED TO STOP THE VEHICLE. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER FOR DIAGNOSIS AND REPAIRED FOR THE FAILURE. THE BRAKES AND COMPUTERIZED SYSTEM WERE REPLACED AT AN ESTIMATED COST OF $5,000. ALSO, THE CALIPERS WERE REPLACED ON A SEPARATE OCCASION. THERE WAS A RECALL UNDER THE NHTSA CAMPAIGN ID NUMBER 09V110000 (SERVICE BRAKES, HYDRAULIC. HOWEVER, THE PART WAS UNAVAILABLE FOR THE RECALL REMEDY REPAIR. THE CONTACT HAD CONCERN OF THE LENGTHY PERIOD OF TIME AND UNCERTAINTY OF THE PART AVAILABILITY FOR THE REPAIR. THE FAILURE MILEAGE WAS 18,000. UPDATED 11/15/10 *CN THE CONSUMER STATED THE RV WAS REPAIRED ON OCTOBER 2010. UPDATED 11/26/10*JB

2003 W22 WORKHORSE CHASSIS. CONSUMER REPORTS BRAKE CALIPER PROBLEMS *TGW IN FEBRUARY 2009 THE ABS SENSORS WERE SERVICED DUE TO THE LIGHT ILLUMINATING. THE CONSUMER STATED HE THEN RECEIVED A RECALL NOTICE REGARDING THE BRAKES, DESPITE BEING TOLD THE BRAKES WERE IN GOOD CONDITION. WHILE DRIVING, THE CONSUMER STARTED TO HEAR A LOW SQUEAL AT LOW SPEED BRAKING. THE CONSUMER STATED AFTER READING THE MANUAL HE CONCLUDED THAT THE SQUEALING WAS NOT A MAJOR PROBLEM. BEFORE TAKING A TRIP, THE CONSUMER DECIDED TO HAVE THE BRAKES INSPECTED. UPON INSPECTION, THE MECHANIC FOUND THAT ONE OF THE PADS HAD WORN DOWN TO THE BARE METAL. WHICH IN TURN, HAD SCORED AND PITTED THE ROTOR TO THE POINT WHERE IT NEEDED TO BE REPLACED. ALL THE OTHER PADS WERE IN GOOD SHAPE. ALSO WHEN THE MECHANIC CHECKED THE BRAKE FLUID RESERVOIR IT CONTAINED A GELLED SUBSTANCE. HE SAID THE FLUID WAS FINE, BUT QUESTIONED WHY THE RESERVOIR FLUID HAD A GELLED LIKE CONSISTENCY.

2004 HOLIDAY RAMBLER MOTOR HOME ON A 2004 WORKHORSE W22 CHASSIS. CONSUMER STATES BRAKE FAILURE *TGW THE CONSUMER STATED HE EXPERIENCED TOTAL EMERGENCY BRAKE FAILURE WITH NO PRIOR WARNING IN APRIL OF 2008 AND AGAIN IN APRIL 2010. BOTH FAILURES WERE EXACTLY AS DESCRIBED IN THE SAFETY RECALL. WORKHORSE DENIED THE CONSUMERS CLAIM IN APRIL 2008 STATING THE FAILURE WAS DUE TO POOR MAINTENANCE. THE SECOND FAILURE RESULTED IN THE CONSUMER HAVING TO HAVE ALL OF THE CALIPERS REPLACED. BOTH OF THE FAILURES WERE A RESULT OF OVERHEATING OF THE BRAKE FLUID CAUSED BY THE CALIPER STICKING IN THE APPLIED POSITION. *JB

TL*THE CONTACT OWNS A 2004 WORKHORSE W22. THE CONTACT RECEIVED A RECALL NOTICE FROM THE MANUFACTURER MAY 2009 AND A SECOND NOTICE DECEMBER 2009 FOR RECALL 09V110000 (SERVICE BRAKES, HYDRAULIC). HE CALLED THE MANUFACTURER THREE TIMES TO FIND OUT WHEN THE PARTS WOULD BE AVAILABLE. THE VEHICLE HAD THE VEHICEL REPAIRED SEVERAL TIMES IN REFERENCE TO THE FAILURE BUT THE MANUFACTURER OFFERED NO REIMBURSEMENT. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 22,000. UPDATED 7/20/10 *CN UPDATED 07/23/10*JB

TL* THE CONTACT OWNS A 2004 WORKHORSE CHASSIS P32 RV. THE CONTACT STATED HE WAS UNABLE TO REMOVE THE GEAR SHIFT SELECTOR OUT OF THE PARK POSITION. HE ATTEMPTED TO APPLY PRESSURE TO THE BRAKE PEDAL TO RELEASE THE GEAR SHIFT LOCK BUT TO NO AVAIL. THE VEHICLE HAD NOT BEEN TAKEN TO AN AUTHORIZED DEALER. THE FAILURE AND CURRENT MILEAGES WERE 8,000.

TL* THE CONTACT OWNS A 2003 WORKHORSE P32 CHASSIS RV. WHILE DRIVING 55 MPH, THE LEFT BRAKES LOCKED AND CAUSED THE VEHICLE TO SWERVE EXCESSIVELY. THE CONTACT WAS ABLE TO MANEUVER THE VEHICLE OFF OF THE ROAD AND ALLOW THE BRAKES TO COOL. THE CONTACT CONTINUED DRIVING TO HIS DESTINATION WITHOUT BRAKES. AN AUTHORIZED WORKHORSE DEALER WAS CONTACTED AND THE DEALER REFUSED TO REPAIR THE VEHICLE. THE MANUFACTURER STATED THAT THERE WERE NO RECALLS ON HIS VEHICLE AND WOULD NOT PROVIDE ANY ASSISTANCE. THE BRAKES WERE REPAIRED AT A LOCAL REPAIR SHOP AT THE OWNERS EXPENSE. THE APPROXIMATE FAILURE MILEAGE WAS 30,700 AND THE CURRENT MILEAGE WAS 30,940. UPDATED 08/03/10. *LJ UPDATED 08/04/10*JB

TL* THE CONTACT OWNS A 2003 WORKHORSE W22 RV. THE CONTACT STATED HE RECEIVED APPROXIMATELY SIX DIFFERENT RECALL AND INTERIM RECALL LETTERS FOR BRAKE FAILURES IN HIS VEHICLE (NHTSA CAMPAIGN ID NUMBER 09V110000: SERVICE BRAKES, HYDRAULIC). IN NOVEMBER 2008, THE CONTACT PHONED THE MANUFACTURER AS HE WAS ADVISED IN THE RECALL LETTER AND WAS INFORMED THAT THE PARTS NEEDED TO COMPLETE RECALL REPAIRS WERE NOT YET AVAILABLE. TWO YEARS AFTER RECEIVING THE INITIAL RECALL LETTER; THE MANUFACTURER WAS STILL STATING THAT THE PARTS WERE NOT YET AVAILABLE. THE CONTACT BELIEVED THE RECALL WAS NOT BEING HANDLED IN A REASONABLE TIME FRAME WHEN DEALING WITH A CONFIRMED SAFETY DEFECT. THE FAILURE MILEAGE WAS APPROXIMATELY 25,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 30,000.