WORKHORSE Complaints

TL* THE CONTACT OWNS A 2002 WORKHORSE W22. THE BRAKE PEDAL WOULD NOT RELEASE AFTER APPLICATION. ALSO THE BRAKE SYSTEM WOULD INTERMITTENTLY OVER-HEAT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, AND A SPRING ON THE BRAKE PEDAL AS INSTALLED. THE REPAIR DID NOT REMEDY THE FAILURE. THE CALIPER GUIDE PIN KIT AND GUIDE PIN BOOT KIN WERE REPLACED. IN 2006, WHILE DRIVING DOWN THE HIGHWAY, HE ATTEMPTED TO USE THE BRAKES AND THEY WERE UNRESPONSIVE. HE ALLOWED THE VEHICLE TO NATURALLY DECELERATE. HE WENT TO ANOTHER AUTHORIZED DEALER, AND THE FRONT WHEEL SEAL, REAR WHEEL SEAL, TWO CALIPERS, TWO BRAKE PAD KITS, AN AXLE GASKET, AND TWO ABS WHEEL SENSORS WERE REPLACED UNDER WARRANTY. ALSO, GREASE ZEROED ALSO INSTALLED ON THE JACK VALVE AT ANOTHER DEALER UNDER WARRANTY . IN 2008, WHILE DRIVING THE BRAKE FAILED AGAIN. HE SHIFTED A VEHICLE INTO A LOWER GEAR AND USED THE EMERGENCY BRAKE TO STOP. HE THEN RECEIVED A RECALL NOTICE IN APRIL OF 2009 (RECALL 09V110000) BUT RECEIVED NO REMEDY. HE SPOKE WITH TWO REPRESENTATIVES IN DECEMBER 2009,WHO TOLD HIM THAT THEY HAD NO WAY OF KNOWING HOW TO REPAIR THE ISSUE. THE CURRENT MILEAGE WAS APPROXIMATELY 34,750. THE FAILURE MILEAGE WAS 8,406.

TL*THE CONTACT OWNS A 2002 NEWMAR MOUNTAIN AIRE RV WITH A W22 WORKHORSE CHASSIS. WHILE DRIVING BETWEEN 55 TO 60 MPH THE CONTACT BEGAN TO SMELL THE BRAKE PADS BURNING. THE CONTACT SHUT THE ENGINE OFF AND EXAMINED THE BRAKES. THE DEALER STATED THAT THE FRONT PASSENGER AND BOTH REAR CALIPERS WERE CRACKED AND NEEDED TO BE REPLACED. ONE YEAR LATER; JULY 2009 WHILE DRIVING APPROXIMATELY 40 MPH THE CONTACT SMELLED THE BRAKES BURNING AGAIN AND TOOK THE VEHICLE TO A DEALER. THE DEALER REPLACED ALL FOUR BRAKE CALIPERS. THE CONTACT RECEIVED A RECALL NOTICE REGARDING BRAKE CALIPERS FROM WORKHORSE. THE CONTACT STATED THAT VEHICLE IS UNSAFE. THE CURRENT MILEAGE WAS 45,000 AND THE FAILURE MILEAGE WAS 36,588. UPDATED 01/12/10 *BF THE FRONT WHEEL OIL SEAL, LEFT FRONT OIL SEAL, BRAKE PADS, MASTER CYLINDER, CALIPERS AND ROTORS WERE ALL REPLACED. THE ABS LIGHT ILLUMINATED AS WELL. UPDATED 01/15/10.*JB

WE DROVE 300 MILES AND FELT THE REAR CALIPERS HANGING UP ON 3 OCCASIONS. AS SOON AS WE GOT ON THE INTERSTATE, WE FELT THE MTRHOME HAD NO POWER, AS IF THE BRAKES WERE BEING APPLIED AND THEN SMELLED BURNING BRAKE ODOR. STOPPED AT THE FIRST REST AREA IN A COUPLE OF MILES, LET THEM COOL FOR 2 HOURS, THEN THEY DID RELEASE AND AS LONG AS WE WERE ON THE INTERSTATE NOT USING BRAKES, WE WERE FINE. AS SOON AS WE GOT OFF THE INTERSTATE TO GO TO THE RV PARK, WITHIN 2 MILES, THE BRAKES ONCE AGAIN HEATED UP BUT NOT ENOUGH TO CAUSE DAMAGE. NEXT DAY WE CONTINUED ON THE INTERSTATE WITH NO PROBLEMS UNTIL WE EXITED IN OCALA. AGAIN, WE DROVE A FEW MILES TO A PARK AND PARKED FOR THE NIGHT. NEXT DAY, DROVE LESS THAN A MILE TO OUR WORKHORSE SERV CTR TO HAVE IT CHECKED. THEY COULD FIND NO DAMAGE TO THE BRAKES SO WERE UNABLE TO AUTHORIZE REPLACEMENT OF THE REAR CALIPERS PER SAFETY RECALL 50901-C. WE, HOWEVER, BEING FAMILIAR WITH THE SYMPTOMS, I.E., SMELL OF BURNING BRAKES, LOSS OF POWER, KNOW THAT THEY WERE IN FACT INTERMITTENTLY HANGING UP. WE OPTED TO REPLACE THE REAR CALIPERS AT OUR EXPENSE($435) SINCE WE DO NOT WANT TO BE STRANDED ON THE SIDE OF THE ROAD AGAIN AS WE HAVE IN THE PAST ON 3 OCCASIONS. WE HAVE REPLACED ALL 4 CALIPERS, 4 ROTORS, BRAKE PADS & FRONT BRAKE LINES AT OUR EXPENSE. WE REQUESTED REIMBURSEMENT ON THE PREVIOUS ISSUES IN JULY, BUT HAVE NOT RECEIVED A RESPONSE. WE CHANGED THE FLUID AND LUBED THE SLIDES PRIOR TO OUR RECENT TRIP. SINCE WE HAVE HAD BRAKE FAILURES ON 8/18/08, 8/21/08 AND 12/4/08 AND 11/24/09 WE KNOW WHAT IT FEELS LIKE TO PUSH THE BRAKE PETAL AND HAVE IT GO ALL THE WAY TO THE FLOOR AND NOT STOP. WE FEEL THAT WE ARE BEING PENALIZED BECAUSE WE ARE CONSCIENTIOUS DRIVERS AND DO NOT CONTINUE DRIVING UNTIL THE CALIPERS ARE SO HOT THEY BURN UP THE WHOLE BRAKE ASSEMBLY. IT SEEMS THAT ONLY THE IRRESPONSIBLE DRIVERS WHO CONTINUE DRIVING UNTIL THE BRAKES ARE TOAST GET REPLACEMENT CALIPERS FROM WH. THIS IS A SAFETY ISSUE THAT IS NOT BEING ADDRESSED. *TR

TL* THE CONTACT OWNS A 2004 WORK HORSE W22 CHASSIS MODEL TIPPING ALLEGRO. DURING BRAKE APPLICATION AT 35 MPH THE PEDAL WENT COMPLETELY TO THE FLOOR. HE ENGAGED THE PARKING BRAKE TO STOP THE VEHICLE. A MECHANIC COULD NOT IDENTIFY THE CAUSE OF THE FAILURE. THE MANUFACTURER STATED A LETTER WAS SENT TO THE OWNERS ADVISING THAT THE CALIPERS COULD CAUSE THE BREAKS TO OVER HEAT AND FAIL. HOWEVER HE NEVER RECEIVED THE LETTER. HE TOOK THE RV TO THE DEALER. THE DEALER STATED THEY WILL NEED TO DUPLICATE THE PROBLEM TO BE ABLE MAKE ANY NECESSARY REPAIRS. HE ADDED THAT IF ANY PARTS WERE REPLACED IT WOULD BE REPLACED WITH THE SAME MATERIAL AND IT WILL NOT BE A PERMANENT REMEDY. THE CURRENT AND THE FAILURE MILEAGES WERE 36,000.

THIS COMPLIANT IS THE SAME AS COMPLAINT # 50901-C. I REQUESTED THAT WORKHORSE REIMBURSE ME FOR MY EXPENSES AND I RECEIVED A LETTER FROM THEM STATING THAT MY COACH DID NOT FALL INTO THE PARAMETER OF THE CAMPAIGN. THIS COACH HAS THE SAME BRAKING SYSTEM THAT IS ON THE ONES MENTIONED IN THE FILE # 50901-C. THIS IS WHAT I REPORTED TO WORKHORSE ON 10/26/2009 "MY WIFE AND I WERE CHECKING OUT CAMPING AREAS IN DEFUNIAK SPRINGS, FL APPROXIMATELY THE FIRST PART OF APRIL 2008. DRIVING DOWN A SMALL INCLINE TO THE PARK I NOTICED THAT THE BRAKES FELT SPONGY AND WOULD NOT STOP THE MOTORHOME NO MATTER HOW MUCH I PRESSED ON THE BRAKES. I PULLED THE PARKING BRAKE AND FINALLY STOPPED BEFORE GOING INTO THE LAKE. I REVERSED UP THE HILL AND DROVE UNTIL I COULD PARK AND ON LEVEL GROUND. UPON CHECKING THE BRAKE FLUIDS I BURNT MY FINGER TOUCHING THE BRAKE FLUID FILLER CAP. AFTER APPROXIMATELY 45 MINUTES I WAS ABLE TO REMOVE THE CAP AND MOST OF THE FLUID HAD BOILED OUT ALL OVER THE WHEEL WELL ON TO THE TIRE. I REFILLED THE BRAKE FLUID AND DROVE BACK TO MILTON, FL REAL SLOW. ON 4/17/08 I CALLED CARPENTER'S CAMPERS IN PENSACOLA, FL ABOUT THE BRAKE PROBLEM AND THEY REFERRED ME TO DAVE HOWELL TIRES, INC. I DROVE TO THEIR SHOP FOR AN INSPECTION (INSPECTION FEE $35.00 INVOICE ATTACHED WITH OTHERS) AND THEY SAID THAT THE RIGHT FRONT WHEEL ROTOR HAD CRYSTALLIZED AND THAT THEY OTHERS HAD DAMAGE. AFTER MUCH NEGOTIATION (STARTED AT $3K PLUS) WE SETTLED UPON THE PARTS AND LABOR PERFORMED ON INVOICE ATTACHED IN THE AMOUNT OF $1621.86. ON THE NEXT TRIP OUT I HAD PROBLEMS WITH THE FRONT TIRES. ON JULY 29, 2008 AND TOOK THE MH TO BEE-LINE IN PENSACOLA TO HAVE IT CHECKED OUT. THEY FOUND THE SWAY BAR BUSHINGS GONE, AIR BAGS NOTHING BUT RAGS AND THAT THE TIRES HAD DAMAGE FROM THE BRAKE FLUID SPILLING ALL OVER THE PLACE. BEE-LINE REPLACED SWAY BAR BUSHINGS $119.00 ON 07/29/08 . ADVANCED TIRES REPLACED FRONT TIRES $395.85 ON 07/31/08. BEE-LINE REPLACED AIR BAGS $499.88 ON 08/01/08. *TR

2007 FLEETWOOD BOUNDER 32W ON A 2007 WORKHORSE W22 CHASSIS HAD BRAKE FAILURE. *NJ THE CONSUMER STATED THE REAR CALIPERS APPARENTLY DRAGGED WHICH CAUSED EXCESSIVE HEAT AND LOSS OF EFFECTIVE BRAKING. AFTER THE CONSUMER RETURNED HOME, HE RECEIVED TWO WARNINGS ON THE DASH WHICH SAID BRAKE FAILURE AND CHECK ABS. THE CONSUMER TRIED THE BRAKES AND THE PEDAL WENT TO THE FLOOR. THE DEALER STATED THE REAR BRAKES AND REAR CALIPER PISTON WERE BINDING. ALSO, THE BRAKE PADS WERE SCORED. *JB

ON OCT 26, 2009, I EXPERIENCED TOTAL BRAKE FAILURE ON 2003 WINNEBAGO MOTOR HOME AT 18,000 MILES. AFTERWARD, I DISCOVERED THE CHASSIS, MANUFACTURED BY WORKHORSE, A DIVISION OF NAVISTAR, IS UNDER A RECALL. NHTSA CAMPAIGN ID NUMBER : 09V110000 MY MOTOR HOME IS UNSAFE TO DRIVE, (STICKING, OVERHEATING BRAKE SYSTEM) AND THE ABS (AUTOMATIC BRAKE SYSTEM) WARNING LIGHT IS ON TELLING ME THERE IS A PROBLEM. WORKHORSE REFUSES TO FIX THE BRAKES TO MAKE IT SAFE TO DRIVE. THEIR POSITION SEEMS TO BE DUAL, 'WAIT UNTIL WE HAVE THE 'FIX' READY, SOMETIME NEXT YEAR.' AND, AT THE SAME TIME, SAYING 'THE STICKING BRAKE SITUATION IS YOUR FAULT.' THIS DUAL STATEMENT SEEMS TO BE THE "LINE" THEY ARE FEEDING TO ALL OF US, AT THIS TIME. IT IS OUTRAGEOUS! ACCORDING TO THEIR REPRESENTATIVES THE RECALL 'FIX' WILL NOT BE AVAILABLE UNTIL SOMETIME NEXT YEAR'..MAYBE. I AM ALSO CONCERNED NAVISTAR AND/OR WORKHORSE COULD ENTER BANKRUPTCY BEFORE THIS ISSUE IS ADDRESSED. THERE ARE THOUSANDS OF US OUT HERE WITH WORKHORSE CHASSIS, MINE IS A WORKHORSE W22, HAVING NEARLY IDENTICAL ISSUES WITH UNSAFE BRAKES. THE SYMPTOM IS THE BRAKE PEDAL GOES TO THE FLOOR RESULTING IN NO BRAKES WITH LITTLE OR NO PRIOR WARNING. AFTER THAT WE DISCOVER THE BRAKES HAVE BEEN STUCK IN THE PARTIALLY APPLIED POSITION WHICH RESULTED IN TREMENDOUS HEAT BEING GENERATED. THAT, IN TURN CAUSES THE BRAKE FLUID TO BOIL. WHEN BRAKE FLUID BOILS IT TURNS TO A GAS. ONCE THIS HAS HAPPENED THE MOTOR HOME HAS NO BRAKES! WORKHORSE, A DIVISION OF NAVISTAR IS DOING LITTLE IF NOTHING AT THIS TIME TO REMEDY THIS VERY DANGEROUS SITUATION AND APPARENTLY HAS TAKEN THE POSITION THAT THE COST TO REMEDY 50,000 MOTOR HOMES WITH DEFECTIVE BRAKES OUTWEIGHS THE RISK OF PUTTING THEIR CUSTOMER'S LIVES IN JEOPARDY. THIS IS OUTRAGEOUS! PLEASE BE AWARE THAT I WILL BE POSTING THIS ALERT TO YOUR DEPT ON THE RV FORUMS ON THE INTERNET. YOU ARE HEREBY NOTIFIED OF THIS DANGEROUS SITUATION. *TR

IN MAY 2009 I RECEIVED NOTIFICATION FROM WORKHORSE CUSTOM CHASSIS THAT OUR MOTORHOME WAS INVOLVED IN SAFETY RECALL 50901-C. THE INFORMATION AVAILABLE TODAY FROM THEIR CUSTOMER SERVICE AND WEBSITE IS THE VERY SAME AS IT WAS IN BACK IN MAY ( PROBLEM IDENTIFIED, PARTS NOT AVAILABLE). I FIND IT HARD TO BELIEVE THAT IN SEVEN MONTHS WORKHORSE HASN'T BEEN ABLE TO RESOLVE THIS SAFETY PROBLEM OR PROVIDE THOSE AFFECTED WITH MORE UP TO DATE INFORMATION ON THE ACTIONS BEING TAKEN. WE LIVE IN OUR MOTORHOME FULL-TIME AND HAVE STOPPED TRAVELING BECAUSE WE HAVE EXPERIENCED SOME OF THE IDENTIFIED PROBLEMS ( ABS LIGHT COMING ON AND MUSHY BRAKES) AS MANY OF US CAN'T GET ANY STRAIGHT ANSWERS FROM WORKHORSE, CAN NHTSA PROVIDE AN UPDATE? *TR UPDATED IVOQ 07/15/10.*JB

REGARDING THE BOSCH BRAKE RECALL, I EXPERIENCED NO BRAKES WHEN THEY OVERHEATED IN AUGUST, 2009. THE BRAKE PEDAL WENT TO THE FLOOR WHEN APPLIED. THANKFULLY I WAS NEAR MY DESTINATION AND CONTACTED A REPAIRMAN THAT INFORMED ME THAT ONCE THEY COOLED DOWN, THE BRAKES WOULD WORK AGAIN AND THEY DID. MY PROBLEM IS THAT I RECENTLY CONTACTED WORKHORSE WHO ADVISED THAT THEY STILL DO NOT THE PARTS TO CORRECT MY RECALL THAT I RECEIVED BACK IN THE EARLY SPRING OF 2009. WHAT'S UP WITH THAT? AM I TO CONTINUE TO RISK MY FAMILY'S LIFE, AS WELL AS OTHERS ON THE ROAD, WHILE THEY OFFER NO DEFINITE SOLUTION? MAYBE A LARGE LAWSUIT AFTER AN ACCIDENT WILL GET THEIR ATTENTION, YOU THINK? *TR

WORKHORSE CHASSIS W22 2004 MILEAGE 17500 MILES BRAKES OVERHEATED, PADS MELTED TO ROTORS ABS SENSOR ON RIGHT WHEEL MELTED. HAD TO REPLACE ROTORS, PADS AND SENSOR. WORKHORSE REFUSE RESPONSIBILITY BECAUSE CALIPER MALFUNCTION DID NOT DESTROY CALIPER ENOUGH EVEN THOUGH THEY ARE AWARE OF PROBLEMS. PARTS WEE LEFT WITH REPAIR SHOP WHO HAS PICTURES. *TR