Odometer readings owners gave when they filed. About half of all
complaints include one.
1,000 – 9,999 miles
218.2%
10,000 – 24,999 miles
545.5%
25,000 – 49,999 miles
436.4%
When owners complained
A spike years after the car went on sale usually means a part wearing
out on schedule across the whole fleet — the kind of pattern no single
owner can see from inside their own car.
Feb 2004peak 2Mar 2009
NHTSA investigations into the 2003 Workhorse W20
An investigation is the step before a recall: the agency has seen enough
complaints to look into a pattern itself. An open one means it thinks
something may be wrong and nothing has been fixed yet.
EA07016Opened 16 Nov 2007Closed 19 Aug 2009SERVICE BRAKES, HYDRAULIC
OVERHEATING DISC BRAKE CALIPER
THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN A...
PE07032Opened 25 Jun 2007Closed 19 Nov 2007SERVICE BRAKES, HYDRAULIC
OVERHEATED BRAKE CALIPERS
ON JUNE 25, 2007, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED OVERHEATING DISC BRAKE CALIPERS AND POOR BRAKE PERFORMANCE IN MODEL YEAR (MY) 2000-2005 WORKHORSE CHASSIS RECREATIONAL VEHICLES.CURRENTLY ODI IS AWARE OF 651 SPECIFIC COMPLAINTS ON THE SUBJECT VEHICLES (ODI AND WORKHORSE COMPLAINT POPULATION).ODI ANALYSIS OF THE WARRANTY AND COMPLAINT DATA FURNISHED BY WORKHORSE ON SEPTEMBER 11, 2007, IN RESPONSE TO ODI'S INFORMATION REQUEST INDICATES A DRAMATIC DROP IN BRAKE RELATED COMPLAINTS AFTER THE MAY 2004 BUILD DATE.AT THAT TIME, WORKHORSE...
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
at 48,850 milesBIG Flats, NY
SERVICE BRAKES, HYDRAULIC
2ND OCCURRENCE OF BRAKE STICKING / DRAG DURING THIS TRIP. R REAR BRAKE DID NOT RELEASE AFTER BRAKING CAUSING DRAG & OVERHEATING. THIS (AND THE PREVIOUS REPORTED INCIDENT) OCCURRED AFTER GOING THROUGH A SECTION OF IN-TOWN STOP & GO TRAFFIC & STOP LIGHTS. THIS OCCURRENCE WAS RECOGNIZED QUICKLY AND WAS NOT AS SEVERE AS THE PREVIOUS ONE. I WAS ABLE TO COOL THE BRAKES DOWN AND THEY RELEASED.
NHTSA complaint #10262913 — an unverified report by a vehicle owner.
at 48,560 milesBIG Flats, NY
SERVICE BRAKES, HYDRAULIC
BRAKE FAILURE - LOCKUP OF FRONT BRAKE CALIPER / ROTOR CAUSING OVERHEATING AND BRAKE FAILURE. NO SERIOUS INJURY RESULTED. CAUSED TRIP DELAY AND SIGNIFICANT COST TO REPAIR REPLACE BRAKE COMPONENTS AFFECTED. DEALER INSPECTED AND DIAGNOSED SIGNIFICANT OVERHEATING AND CRACKING OF THE FRONT ROTORS AND RECOMMENDED REPLACEMENT OF SAME AND PADS & SEALS AT A COST OF APPROX $900. THIS UNIT WAS PURCHASED USED WITH APPROX 37600 MILES AT WHICH TIME THE DEALER (WH SERVICE CENTER) INSPECTED AND REPLACE BRAKE PADS ON ALL 4 WHEELS. THIS UNIT IS STORED FOR SEVERAL MONTHS AT A TIME BUT HAS ALWAYS BEEN INSIDE STORAGE AND THE UNIT IS NOT DRIVEN IN WINTER WEATHER.
NHTSA complaint #10262068 — an unverified report by a vehicle owner.
Nesconset, NY
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS
LTR FROM CONGRESSMAN BISHOP ON BEHALF OF CONSTITUENT RE AN UPDATE ON AN INQUIRY HE PREVIOUSLY SUBMITTED RE W20 AND W22 CHASSIS BRAKES. *NJ THE CONSUMER STATED THE REAR BRAKE ROTORS OVERHEATED. THE BOILING BRAKE FLUID ALSO LEAD TO THE BRAKE FAILURE.
NHTSA complaint #10259068 — an unverified report by a vehicle owner.
at 8,681 milesSyracuse, NY
SERVICE BRAKES, HYDRAULIC
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.
NHTSA complaint #10239439 — an unverified report by a vehicle owner.
at 15,962 milesOceanside, CA
SERVICE BRAKES, HYDRAULIC
WHILE MY 2003 FLEETWOOD SOUTHWIND MOTOR HOME ON A WORKHORSE CHASSIS WAS IN FOR A RECALL ON THE INSTRUMENT CLUSTER (ABS) I WAS INFORMED THAT MY BRAKE FLUID HAD OVER HEATED AND THE BRAKE SYSTEM REQUIRED REPLACEMENT (CALIPERS, PADS, ROTORS). ACCORDING TO THE DEALER THE FLUID OVERHEATED, TURNED TO A JELLY AND WOULD NOT ALLOW THE PISTONS TO RETRACT AFTER THE BRAKES HAD BEEN APPLIED. WORHORSE WAS CONTACTED BY DEALER AND THEY REFUSED TO ACKNOWLEDGE THERE WAS AN ISSUE WITH THE BRAKES. I RETAINED 2 OF THE BRAKE CALIPERS AFTER REPAIRS WERE COMPLETE. RELATED TO NHTSA EA07016.
NHTSA complaint #10233626 — an unverified report by a vehicle owner.
at 27,684 milesSturtevant, WI
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC
WE HAVE A 2003 MOTORHOME WITH A W20 WORKHORSE FRAME. I HAVE LOST THE HYDRAULIC BRAKES DUE TO THE FLUID BOILING TWICE DURING NORMAL DRIVING ON LEVEL ROADS (NO HILLS OR MOUNTAINS) BOTH TIMES THE HEAT DESTROYED THE ABS WHEEL SENSORS.
NHTSA complaint #10225639 — an unverified report by a vehicle owner.
at 27,200 milesPearl River, LA
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER
REAR BRAKES OVERHEATING. NO COMPLETE FAILURE. ONLY CAUSED LOSS OF RV VACATION AND MAJOR INCONVENIENCE. PULLED OFF TO SIDE OF ROAD TO ALLOW COOL DOWN. DELIVERED TO MECHANIC FOR FLUID CHANGE AND CHECKING AND LUBRICATING OF CALIPERS. THIS SAME THING HAPPENED 10 MONTHS LATER.
NHTSA complaint #10220759 — an unverified report by a vehicle owner.
at 16,000 milesClearwater, FL
SERVICE BRAKES, HYDRAULIC
TL*THE CONTACT OWNS A 2003 WORKHORSE W20. WHILE DRIVING 40 MPH, THE VEHICLE WOULD NOT ACCELERATE AS FAST AS IT NORMALLY WOULD. IN ADDITION, THE CONTACT NOTICED A BURNING SMELLING COMING FROM THE REAR OF THE VEHICLE. THE MECHANIC STATED THAT THE CALIPERS CAUSED THE FAILURE AND THEY REPLACED THE LEFT AND RIGHT REAR BRAKE CALIPERS. THERE IS AN OPEN DEFECT INVESTIGATION FOR THE SERVICE BRAKES: HYDRAULIC (NHTSA ACTION NUMBER EA07016). THE FAILURE MILEAGE WAS 16,000 AND CURRENT MILEAGE WAS 17,000. UPDATED 02-06-08. *KB THE CONSUMER STATED AT THE FIRST OBSERVATION THE LEFT REAR CALIPER WAS EXTREMELY HOT TO THE TOUCH AND ALL OTHER CALIPERS SEEMED TO HAVE NORMAL TEMPERATURE. UPDATED 02/06/08
NHTSA complaint #10213573 — an unverified report by a vehicle owner.
at 15,100 milesNesconset, NY
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
TL*THE CONTACT OWNS A 2003 DAMON WORKHORSE (NA). WHILE DRIVING 30 MPH, THE CONTACT WAS FLAGGED DOWN BY ANOTHER MOTORIST AND ADVISED TO PULL OVER. ONCE HE PULLED OFF THE ROAD, HE DISCOVERED THAT THE BRAKES FAILED. HE STOPPED THE VEHICLE WITH THE EMERGENCY BRAKE. THE VEHICLE WAS TOWED TO HIS RESIDENCE. WHEN THE WHEELS WERE REMOVED FROM THE VEHICLE, THE BRAKE SHOES WERE FINE, HOWEVER, THE LEFT REAR WHEEL OVERHEATED AND CAUSED THE CALIPER TO BOIL THE BRAKE FLUID. HE WAS INFORMED THAT THE CALIPERS AND BRAKE ROTORS NEEDED TO BE REPLACED. THE CURRENT AND FAILURE MILEAGES WERE 15,100. UPDATED 01/24/08 . *LJ UPDATED
NHTSA complaint #10205270 — an unverified report by a vehicle owner.
at 15,100 milesNesconset, NY
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER
TL*THE CONTACT OWNS A 2003 DAMON WORKHORSE (NA). WHILE DRIVING 30 MPH, THE CONTACT WAS FLAGGED DOWN BY ANOTHER MOTORIST AND ADVISED TO PULL OVER. ONCE HE PULLED OFF THE ROAD, HE DISCOVERED THAT THE BRAKES FAILED. HE STOPPED THE VEHICLE WITH THE EMERGENCY BRAKE. THE VEHICLE WAS TOWED TO HIS RESIDENCE. WHEN THE WHEELS WERE REMOVED FROM THE VEHICLE, THE BRAKE SHOES WERE FINE, HOWEVER, THE LEFT REAR WHEEL OVERHEATED AND CAUSED THE CALIPER TO BOIL THE BRAKE FLUID. HE WAS INFORMED THAT THE CALIPERS AND BRAKE ROTORS NEEDED TO BE REPLACED. THE CURRENT AND FAILURE MILEAGES WERE 15,100. UPDATED 01/24/08 . *LJ UPDATED
NHTSA complaint #10205270 — an unverified report by a vehicle owner.
at 21,880 milesAlpharetta, GA
SERVICE BRAKES, HYDRAULIC
BRAKE FAILURE. REAR BRAKES OVERHEATED AND BOILED THE BRAKE FLUID. COACH WAS TOWED TO CAMPING TIME RV IN OAKWOOD, GA. IT HAS BEEN THERE FOR OVER A MONTH AWAITING PARTS. BRAKE PEDAL WENT TO THE FLOOR. REAR HUBS TOO HOT TO TOUCH AND BOILED THE BRAKE FLUID.*JB UPDATED 01/11/08. *LJ THE MASTER CYLINDER WAS DEFECTIVE. UPDATED
NHTSA complaint #10201867 — an unverified report by a vehicle owner.
at 7,300 milesWyoming, MI
SERVICE BRAKES, HYDRAULIC
BRAKES FAILED AT BELOW FREEZING TEMP.EXTREME PRESSURE HAD TO BE APPLIED TO GET MINIMAL BRAKE PRESSURE AFTER WHICH I HAD TO PULL BRAKE PEDAL UP BY HAND. THE BRAKE PEDAL WAS FROZE TO THE TOP.
NHTSA complaint #10056768 — an unverified report by a vehicle owner.