WORKHORSE Complaints

ON 9/6/07, THE L.F. BRAKE ON MY MOTORHOME SEIZED UP AND OVERHEATED THE BRAKE ROTOR FOR ALMOST 10 MILES UNTIL I NOTICED SEVERE SHAKING IN THE STEERING WHEEL & SMELLED "BURNT BRAKE LINING" WHEN I STOPPED. I WAS DRIVING IN NORMAL CITY TRAFFIC NEAR ALLIANCE, OHIO; -NOT EXCESSIVE STOP AND GO, BUT THERE WAS MAYBE 4 RED LIGHTS OVER THE COURSE OF 3 MILES DISTANCE (AT 30 MPH) TO STOP. MY STOPPING WAS "NORMAL", NOT SUDDEN OR ERRATIC. THE LEFT FRONT HUB & WHEEL GOT SO HOT FROM THE CALIPER/BRAKE ASSY. SEIZING THAT IT BOILED AWAY ALL OF THE 90W LUBE ON THE WHEEL BEARINGS AND BLEW OUT THE RUBBER PLUG ON THE LUBE SIGHT GLASS. I LET IT COOL DOWN FOR AN HOUR, THEN LOOKED AT THE INNER SIDE OF THE L.F. WHEEL TO SEE IF I'D HAVE TO LOOSEN/PRY AWAY THE SEIZED BRAKE PAD OR CALIPER ASSEMBLY. SURPRISE, THE BRAKE PADS WERE ALREADY SITTING BACK AWAY FROM THE ROTOR; -THE CALIPER HAD APPARENTLY RETRACTED BY ITSELF AFTER COOLING DOWN. I PROCEEDED SLOWLY TO THE CAMPGROUND, 5 MILES AWAY, AND MADE ARRANGEMENTS TO GET SOME 90W LUBE OIL. LUBE WAS REPLACED THE NEXT DAY AND THE WHEEL BEARINGS STILL FELT GOOD; ANOTHER SIGHT CAP SEAL WAS INSTALLED. ON 9/12/07, I TOOK THE COACH TO MAINLINE TRUCK & TRAILER (A WORKHORSE CHASSIS SERVICE DEALER) IN SOLON, OHIO, FOR SERVICE. IN A NUTSHELL, I ENDED UP PAYING $828.28 TO REPAIR THE DAMAGE AND SERVICE MY COACH FOR FUTURE "PEACE OF MIND". THE FOLLOWING WORK WAS PERFORMED: SERVICED ALL CALIPER SLIDE PINS, LUBE, & BOOTS ON ALL 4 WHEELS; CONFIRM CORRECT CALIPER OPERATION ON ALL 4; REPLACE ABS WHEEL SENSOR ON LEFT FRONT; RESET ABS WARNING LIGHT; INSPECT ALL 4 ROTORS FOR CRACKS; REPLACE LF WHEEL BEARING INNER SEAL; INSPECT LF BEARINGS; INSPECT REAR AXLE HUB SEALS; ETC. ON 9/18/08, AT 11,891 MILES, MY RIGHT FRONT BRAKE SEIZED UP UNEXPECTEDLY! THIS TIME ALONG A 45 MPH STATE HWY WITH VERY INFREQUENT BRAKING. I BELIEVE THE PROBLEM HERE IS FAULTY ABS CONTROLLER AND OR THE BOSCH BRAKES. THEY DO NOT ALWAYS RELEASE THE CALIPERS. WORKHORSE IGNORES THIS PROBLEM! *TR

WE CURRENTLY OWN A 2004 ALLEGRO BAY 34XB MOTOR HOME ON WORKHORSE W22 CHASSIS . AT THE TIME OF THE OCCURRENCE IT HAD APPROXIMATELY 14250 MILES ON THE CHASSIS. AFTER DRIVING FROM MYRTLE BEACH ABOUT 35 MILES ON JULY 30, 2008 WE STOPPED TO REFUEL AND SMELLED BURNING BRAKE PADS IN THE REAR OF THE VEHICLE. WHEN WE STARTED BACK OUT THE ABS WARNING LIGHT CAME ON AND STAYED ILLUMINATED. SINCE IT WAS LATE IN THE DAY WE DECIDE TO RETURN HOME AND TRY TO GET THE VEHICLE CHECKED THE FOLLOWING MORNING. ON THE WAY HOME WE EXPERIENCED A REDUCTION IN BRAKE PERFORMANCE WHEN STOPPING. ON JULY 31, 2008 WE BROUGHT THE VEHICLE TO LARRY'S AUTO CLINIC AN AUTHORIZED WORKHORSE SERVICE CENTER IN MYRTLE BEACH. ACCORDING TO THE SERVICE CENTER THE CALIPER CAN HANG UP AND CAUSE THE BRAKE PADS TO DRAG ON THE ROTOR SURFACE. OVERHEATING OCCURS, CAUSING DAMAGE TO THE BRAKE COMPONENTS AND AFFECTING BRAKING PERFORMANCE. THE PROBLEM ALSO CAUSES THE BRAKE SYSTEM'S ANTILOCK FEATURES TO BE LOST WHEN THE HEAT DAMAGES THE ANTILOCK WHEEL SENSOR. THEY DETERMINED THAT THE REAR BRAKING SYSTEM HAD BEEN DAMAGED AND NEEDED TO BE REPLACED AS WELL AS THE ABS SENSOR.*TR

1. RANDOM LOCK UP OF VEHICLE BRAKES 2. OCCURRED SEPTEMBER 2006 AND AGAIN IN AUGUST 2008. EXTREME VEHICLE VIBRATION AND LOSS OF STEERING. BRAKES SMOKE AND BECOME EXTREMELY HOT. 3. VEHICLE CHECKED BY LES SCHWAAB TIRE STORE AND AUTHORIZED GM REPAIR CENTER. CHARGED FOR INSPECTION. NEITHER SHOP COULD DIAGNOSE CAUSE OR REPAIR NEEDED. *TR

TOOK VEHICLE INTO DEALER AND HAD CAMPAIGN NUMBER 04V019000 COMPLETED ON 10-26-04. NOW LESS THAN 10,000 MILES SINCE THEN, IT IS BACK AT THE SERVICE CENTER AFTER BRAKE FIRE AND PEDAL LOSS. VEHICLE IS IN NEED OF ROTORS, CALIPERS AND WHEEL SPEED SENSOR. *TR

PARTIAL LOCKUP OF REAR CALIPERS ON A 2003 WORKHORSE W-20 CHASSIS ON A 2004 FLEETWOOD FLAIR 33R MOTORHOME AFTER TRAVELING APPROXIMATELY 100 MILES ON RELATIVELY FLAT HIGHWAY ENTERING TRAFFIC WITH STOPLIGHTS. AFTER ABOUT 10 MILES IN THE STOP AND GO TRAFFIC, A SLIGHT 'BRAKE SMELL' WAS NOTICED. THIS WAS APPROXIMATELY 10 MILES FROM HOME. I GOT OUT AND CHECKED THE WHEELS AND BOTH REAR WHEELS WERE HOT TO THE TOUCH. AT APPROXIMATELY 1 MILE FROM HOME THE ABS LIGHT CAME ON AND THE BRAKE PEDAL WENT TO THE FLOOR. WHEN THIS HAPPENED, I PUMPED THE PEDAL A FEW TIMES AND HAD BRAKES. I LIMPED HOME IN THIS CONDITION. PARKED AT HOME I NOTICED THE MASTER CYLINDER WAS HOT, THE BRAKE LINE TO THE REAR BRAKES WAS HOT, A SENSOR HAD MELTED OFF THE RIGHT REAR DUAL, AND A LENGTH (APPROX. 18 INCHES) OF FINE, COILED, COPPER WIRE WAS HANGING FROM THE CALIPER. TO ME IT LOOKED LIKE IT CAME OUT OF THE MELTED SENSOR. THE LEFT WHEEL WAS HOT, AND NOTHING WAS MELTED. AN APPOINTMENT WAS MADE TO GET IT LOOKED AT ON 8/26/08. *TR

WHILE TRAVELING IN OUR RV FOR NO APPARENTLY REASON, WE SUDDENLY BEGAN TO SMELL BURNING BRAKES, THEN THE STEERING BEGAN TO SHIMMY AND VIBRATE. WHEN THE BRAKE WAS APPLIED THE VIBRATION INCREASED. I IMMEDIATELY PULLED OFF AT A SAFE AREA, UNHOOKED MY TOW VEHICLE AND WENT FOR ASSISTANCE. ALL FOUR ROTORS AND BRAKE PADS WERE REPLACED AT A COST OF $2209.89. THIS IS THE FIRST TIME WE HAVE EXPERIENCED ANY PROBLEMS WITH OUR BRAKES AND IT HAPPENED SUDDENLY WITH NO WARNING. THE OLD PARTS WERE SENT BACK AS "CORE" PARTS BY THE REPAIR FACILITY. WE ARE NOW AWARE OF NHTSA EA07-016 INVOLVING BOSCH BRAKE CALIPERS OVERHEATING, CAUSING THE ROTORS TO GO BAD AND BELIEVE OUR WORKHORSE CHASIS WHICH DOES HAVE THIS BRAND OF CALIPERS HAS EXPERIENCED THE SAME PROBLEM AS WAS DESCRIBED IN THIS BULLETIN. UPON COMPLETION OF THIS REPAIR, WE PROCEEDED ON OUR TRIP. ABOUT 75 MILES FARTHER, WE AGAIN SMELLED BRAKES BURNING. WE PULLED OFF THE ROAD AS FAST AS WE COULD AND CALLED OUR ROADSERVICE. THE PASSENGER SIDE FRONT BRAKE WAS SMOKING. THEY SENT OUT A MOBILE REPAIR TECH WHO REMOVED THE TIRE/WHEEL, REMOVED THE CALIPER AND LUBRICATED THE CALIPER SLIDE. THE CALIPER SEEMED TO BE WORKING NORMALLY, HOWEVER, WE ARE AT A LOSS AS TO WHAT ACTUALLY CAUSED OUR PROBLEM AND ARE CONCERNED THAT THE CAUSE HAS NOT BEEN ADDRESSED AND IT WILL REOCCUR. *TR

HAD BRAKE RECALL IN 2/06. BRAKES NEARLY FAILED 7/08 ON TRIP OUT WEST. ABS SENSOR BAD, FRONT BRAKE PADS BAD, AND LEFT FRONT CALIPER BAD. THIS CORRESPONDS TO TROUBLES OTHER DRIVERS HAVE HAD WITH THIS SYSTEM. *TR

OPERATING A 2004 FLEETWOOD PACE ARROW 35G MOTORHOME ON A WORKHORSE CHASSIS W22, FLAT TOWING A 2002 HONDA CIVIC. TRAVELING RT 41 IN PA. FROM NEW JERSEY. I WAS OPERATING IN MILD TO LIGHT TRAFFIC ON A HILLY ROAD BETWEEN AVONDALE AND GAP, PA. AT FIRST I SMELLED WHAT I THINK WAS AND ELECTRICAL SCENT. SOON AFTER I LOSS BRAKE PEDAL PRESSURE. PUMPING THE PEDAL IMPROVED BRAKE USAGE. PERSONALLY EXAMINED THE MASTER AND ALL FOUR BRAKES UNDER THE MOTORHOME FOR FLUID LOSS. NONE OBSERVED NEXT DAY DROVE SHORT DISTANCE TO A QUALITY AUTO / TRUCK REPAIR IN GAP, PA. AND INFORMED THEM OF THE INCIDENT AND REQUESTED THEY SURVEY THE BRAKE SYSTEM FOR PROBLEMS. THEY FOUND NONE. DROVE BACK HOME TO EGG HARBOR TWP., NJ WITHOUT A PROBLEM. *TR

TOOK MOTORHOME (WORKHORSE W22 CHASSIS) TO GET GAS, APPROX 5 MILES. GOT GAS AND RETURNED. LITTLE TRAFFIC, FLAT ROAD, 45 MPH. UPON RETURN, BOTH FRONT BRAKE ROTORS WERE SMOKING. THIS FOLLOWS PREVIOUS FAILURES OF BOTH REAR BRAKES. MOTORHOME HAS LESS THAN 24,000 MILES AND HAS BEEN WELL MAINTAINED, INCLUDING TWO COMPLETE REPLACEMENTS OF BRAKE FLUID. NOTIFIED WORKHORSE AND THEY RESPONDED THAT THE VEHICLE IS OUT OF WARRANTY AND NOT INVOLVED IN ANY BRAKE RECALLS. THIS REPORT IS A DUPLICATE OF 10237294 WHICH WAS FILED UNDER THE MOTORHOME NAME INSTEAD OF THE WORKHORSE CHASSIS. *TR

ON SEP. 12 OF 2007, WE LEFT ON A TRIP FROM OUR HOME TO LAS VEGAS, NV. ON THE FIRST LEG OF OUR TRIP OUR WE NOTICED WE WERE GETTING VERY POOR GAS MILEAGE AND IT SEEMED LIKE OUR BRAKES WERE DRAGGING. WE PULLED OVER AT THE WELCOME CENTER IN LOUISIANA ON I-59. WE NOTICED THE REAR BRAKES SMELLED HOT. WHEN WE WENT BACK INTO THE MOTORHOME AND STARTED IT BACK UP THE "ABS" WARNING LIGHT WAS ON. WE THEN CALLED A WORKHORSE SERVICE CENTER, ROSS DOWNING CHEVROLET. THE MECHANIC TOLD US TO WAIT FOR AN HOUR AND DRIVE IT TO HAMMOND TO THE DEALERSHIP AND HE WOULD WORK ON IT. THE MECHANIC REPLACED THE REAR ROTORS, CALIPERS, PADS AND WHEEL SENSORS, THEN RESET THE "ABS" WARNING LIGHT. ALL WAS GOOD UNTIL WE WENT OVER THE HOOVER DAM AND THE ABS LIGHT CAME BACK ON AND WE PULLED OVER AND LET THE BRAKES COOL DOWN AGAIN AND THEN DROVE TO OUR CAMPGROUND AT NELLIS AIR FORCE BASE IN LAS VEGAS. THEN ONCE WE WERE THERE WE CALLED AND MADE AN APPOINTMENT WITH FINDLAY RV. THEY REPLACED THE WHEEL SENSOR ON THE FRONT LEFT WHEEL. AND RESET THE CODES. THE DATE OF THE FRONT WHEEL INCIDENT WAS APPROX. SEP 21 2007. NOW FOR THE MOST RECENT INCIDENT. AUGUST 7, 2008, WE WERE TRAVELING TO BILOXI, MS FROM OUR HOME AND I NOTICED OUR GAS MILEAGE DECREASING AGAIN. WE PULLED OVER AND SMELLED THAT THE LEFT FRONT WHEEL AREA WAS HOT. WE LET THE BRAKES COOL AGAIN AND FROM OUR PREVIOUS EXPERIENCE AND BECAUSE WE ARE SO CLOSE TO HOME WE DECIDED TO JUST GO AHEAD AND STAY IN BILOXI BECAUSE I HAD AN APPOINTMENT AT THE VA CENTER IN BILOXI THE NEXT DAY. WE ARE GOING TO TAKE THE MOTORHOME TO A SERVICE CENTER TO HAVE THE "ABS" WARNING LIGHT CHECKED OUT AND REPAIRED. I BELIEVE THAT 3 TIMES IN A YEAR IS A BIT EXCESSIVE TO HAVE PROBLEMS WITH THE "ABS" SYSTEM AND NEEDS TO BE INVESTIGATED ESPECIALLY SINCE OUR MOTORHOME IS ONLY 4 YEARS OLD. ALSO, MY PARENTS OWN A 2003 WORKHORSE W22 CHASSIS ALSO AND HAVE HAD PROBLEMS WITH THEIR "ABS" WARNING LIGHT ALSO. *TR