Owners have filed 130 complaints
about the 2003 Workhorse W22 with NHTSA between 2005 and 2022.
The largest single group is the brakes.
Across this model's run it ranks 1 of 5 worst.
The letter says how bad. This says what kind — whether this year drew
an unusual number of complaints, unusually dangerous
ones, or failures that arrived unusually early.
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 93
Against the median year of the Workhorse W22. 50 means typical for this
model; 100 means roughly double.
Severity — 44
8.5% of these complaints
involved a crash, fire, injury or death, against a national rate of
9.7%.
Early failure — 100
84% of failures with a mileage on record happened under
36,000 miles, against a national rate of
29%.
Odometer readings owners gave when they filed. About half of all
complaints include one.
1,000 – 9,999 miles
910.3%
10,000 – 24,999 miles
4450.6%
25,000 – 49,999 miles
3135.6%
50,000 – 74,999 miles
33.4%
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.
Jul 2005peak 13Jan 2022
NHTSA investigations into the 2003 Workhorse W22
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...
Complaints that involved harm
Reports where the owner recorded a crash, a fire, an injury or a death.
at 54,000 milesHortense, GAFire
SERVICE BRAKES, HYDRAULIC
The contact owns a 2003 Workhorse W22. The contact stated that upon stopping the motorhome in her driveway, her husband discovered a bluish-black color smoke emitting from underneath the vehicle. The rear passenger side brake caliper had caught fire and the contact's husband was able to extinguish the fire with a water hose. The fire department was not called and a report was not filed. The contact stated that the brake and ABS warning lights had illuminated on the instrument panel after the failure. The contact's husband took pictures of the damage and showed them to an independent mechanic. The mechanic then informed the contact's husband of NHTSA Campaign Number: 09V110000(SERVICE BRAKES, HYDRAULIC) which he linked to the failure. The mechanic contacted then notified the manufacturer of the failure but received no assistance. The contact also made multiple attempts to reach the manufacturer but had no success. The vehicle had yet to be repaired. The failure mileage was approximately 54,000.
NHTSA complaint #11447460 — an unverified report by a vehicle owner.
at 20,000 milesPolk City, FLFire
SERVICE BRAKES, HYDRAULIC
TL* THE CONTACT OWNS A 2003 REX HALL AERBUS MOTOR HOME, WITH A WORKHORSE W22 CHASSIS. WHILE DRIVING 60 MPH HE ENGAGED THE BRAKES AND BEGAN TO SMELL SOMETHING BURNING. THE CONTACT STATED HE PULLED INTO AN RV CAMP GROUND AND INSPECTED THE VEHICLE. THE VEHICLE WAS DRIVEN TO AN AUTHORIZED DEALER, THE DEALER REPLACED ALL FOUR BRAKE CALIBERS. HE STATED THE MANUFACTURER WAS REFUSING TO REIMBURSE HIM FOR THE REPAIRS SINCE HIS VEHICLE WAS NOT PART OF THE FIRST RECALL. HE REFERENCE RECALL 09V110000, SERVICE BRAKES, HYDRAULIC AND STATED HE RECEIVED THIS RECALL RECENTLY. THE CONTACT STATED HE HAS NOT HAD THE ABOVE RECALL REPAIR PERFORMED. THE FAILURE MILEAGE WAS 20,000 AND THE CURRENT MILEAGE WAS 22,800.
NHTSA complaint #10356949 — an unverified report by a vehicle owner.
at 21,000 milesNort Vernon, INFire
SERVICE BRAKES, HYDRAULIC
TL*THE CONTACT OWNS A 2003 WINNEBAGO ADVENTURER 38L WITH A WORKHORSE W22 CHASSIS. WHILE DRIVING APPROXIMATELY 60 MPH HE ENGAGED THE BRAKES AND SMELLED SOMETHING BURNING. HE PULLED OVER INTO A REST AREA UNTIL THE VEHICLE COOLED OFF. HE STATED THAT THE ABS LIGHT CAME ON AND STAYED ON. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER. THE DEALER CLEANED AND REMOVED ALL OF THE WHEEL SENSORS. A MONTH LATER THE ABS LIGHT CAME ON AGAIN. THE VEHICLE WAS TAKEN BACK TO THE SAME DEALER WHO REMOVED AND CLEANED ALL OF THE ABS SENSORS, THE CALIPERS AND ROTORS. TWO NEW REAR SENSORS WERE ALSO INSTALLED. LESS THAN A MONTH LATER, THE ABS LIGHTS ILLUMINATED AGAIN. THE VEHICLE WAS NOT REPAIRED. THE CONTACT REFERENCED RECALL 09V110000, SERVICE BRAKES, HYDRAULIC. THE CONTACT STATED THAT THE VEHICLE HAD NOT BEEN USED SINCE APRIL 2010. THE FAILURE MILEAGE WAS 21,000 AND THE CURRENT MILEAGE WAS 23,700.
NHTSA complaint #10356838 — an unverified report by a vehicle owner.
at 18,700 milesMoreno Valley, CAFire
SERVICE BRAKES, HYDRAULIC
TL* THE CONTACT OWNS A 2003 WORKHORSE W22 RV. THE CONTACT STATED THAT HE RECEIVED NOTIFICATION OF NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC) IN 2009 AND RECEIVED A SECOND NOTICE SHORTLY AFTER STATING THAT THE PARTS WERE NOT AVAILABLE FOR THE RECALL REPAIR. THE CONTACT TOOK THE VEHICLE TO AN AUTHORIZED DEALER FOR REPAIRS, WHICH WOULD INCLUDE REPLACING THE ROTORS, BRAKE FLUID, SEALS, AND OTHER PARTS. THE MANUFACTURER STATED THERE WERE NO FAILURES WITH THE CALIPERS THEREFORE; REPAIRS WOULD BE DONE AT THE OWNERS EXPENSE. THE CONTACT DID NOT FEEL SAFE DRIVING THE VEHICLE. THE FAILURE MILEAGE WAS APPROXIMATELY 18,700.
NHTSA complaint #10336207 — an unverified report by a vehicle owner.
at 3,000 milesPoughkeepsie, NYFire
SERVICE BRAKES, HYDRAULIC
TL* THE CONTACT OWNS A 2003 REXHALL REXAIR RV, WITH A WORKHORSE CHASSIS W22. WHILE DRIVING APPROXIMATELY 60 MPH HE SMELLED A BURNING ODOR FROM THE BRAKES. DURING BRAKE APPLICATION, THE PEDAL WENT TO THE FLOOR, BUT THE VEHICLE WOULD NOT STOP. THE FAILURE OCCURRED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION. HIS VEHICLE IDENTIFICATION NUMBER WAS EXCLUDED FROM RECALL CAMPAIGN ID NUMBER 09V110000 (SERVICE BRAKES, HYDRAULIC). NO REPAIRS WERE MADE. THE FAILURE MILEAGE WAS 3,000. THE CURRENT FAILURE MILEAGE WAS 42,000.
NHTSA complaint #10296224 — an unverified report by a vehicle owner.
at 17,406 milesHotsprings, VAFire
SERVICE BRAKES, HYDRAULIC
TL*THE CONTACT OWNS A 2003 WORKHORSE W22. WHILE SPORADICALLY DEPRESSING THE BRAKE PEDAL, THE VEHICLE FAILED TO STOP. UPON FURTHER INSPECTION, THE CONTACT NOTICED THAT THE BRAKE FLUID WAS BUBBLING DUE TO EXCESSIVE HEAT EXPOSURE. HE TOOK THE VEHICLE TO THE DEALER BECAUSE THREE OF THE ABS WHEEL SENSORS BURNED OFF AND TWO OF THE ABS SEALS FAILED. THE TECHNICIAN REPLACED THE BRAKE CALIPERS AND THE SEALS AT MORE THAN $1,000. THE MANUFACTURER WOULD NOT ASSIST BECAUSE THERE WAS NO RECALL. THE FAILURE AND CURRENT MILEAGES WERE NOT APPLICABLE. UPDATED 03/27/09 *BF THE CONSUMER STATED ON 2 SEPARATE OCCASIONS, HE HAD TO PULL OVER AND WAIT FOR THE BRAKES TO COOL OFF. THE THIRD TIME, THE BRAKES SEIZED. THE CALIPER WAS REPLACED. UPDATED 04/01/09.
NHTSA complaint #10254096 — an unverified report by a vehicle owner.
The most recent complaints
In the owners' own words, exactly as filed with NHTSA.
at 54,000 milesHortense, GAFire
SERVICE BRAKES, HYDRAULIC
The contact owns a 2003 Workhorse W22. The contact stated that upon stopping the motorhome in her driveway, her husband discovered a bluish-black color smoke emitting from underneath the vehicle. The rear passenger side brake caliper had caught fire and the contact's husband was able to extinguish the fire with a water hose. The fire department was not called and a report was not filed. The contact stated that the brake and ABS warning lights had illuminated on the instrument panel after the failure. The contact's husband took pictures of the damage and showed them to an independent mechanic. The mechanic then informed the contact's husband of NHTSA Campaign Number: 09V110000(SERVICE BRAKES, HYDRAULIC) which he linked to the failure. The mechanic contacted then notified the manufacturer of the failure but received no assistance. The contact also made multiple attempts to reach the manufacturer but had no success. The vehicle had yet to be repaired. The failure mileage was approximately 54,000.
NHTSA complaint #11447460 — an unverified report by a vehicle owner.
Grass Valley, CA
SERVICE BRAKES
NAVISTAR IS RECALLING.....THERE'S A RECALL TO REPLACE ALL FOUR CALIPERS BUT THEY WON'T REPLACE THE ROTORS ALL FOUR OF THEM ARE CRACKED FROM OVERHEATING BECAUSE OF THE CALIPERS HANGING UP . THIS RECALL IS FOR A WORKHORSE W22 CHASSIS.
NHTSA complaint #11111288 — an unverified report by a vehicle owner.
at 39,625 milesFort Myers, FL
SERVICE BRAKES
REAR CALIPERS WERE REPLACED ON RECALL WITH REBUILT CALIPERS. AFTER LESS THAN 500 MILES THE RIGHT REAR CALIPER BLEW OUT ALL BRAKE FLUID RESULTING IN COMPLETE LOSS OF BRAKES. THIS HAPPENED 40 MILES FROM HOME ON A STATE ROAD.
NHTSA complaint #10876563 — an unverified report by a vehicle owner.
NEW Concord, OH
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED.
NHTSA complaint #10440813 — an unverified report by a vehicle owner.
NEW Concord, OH
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS
2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED.
NHTSA complaint #10440813 — an unverified report by a vehicle owner.
NEW Concord, OH
EXTERIOR LIGHTING:TURN SIGNAL:SWITCH
2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED.
NHTSA complaint #10440813 — an unverified report by a vehicle owner.
NEW Concord, OH
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED.
NHTSA complaint #10440813 — an unverified report by a vehicle owner.
NEW Concord, OH
SERVICE BRAKES, HYDRAULIC
2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED.
NHTSA complaint #10440813 — an unverified report by a vehicle owner.
NEW Concord, OH
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
2003 NEWMAR MOUNTAIN AIRE MOTORHOME ON A 2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO WORKHORSE BRAKE SYSTEM RECALL *TGW THE CONSUMER STATED IN MAY OF 2009, HE RECEIVED AN INTERIM NOTICE WARNING ABOUT A POSSIBLE PROBLEM WITH THE WORKHORSE SYSTEM. THE NOTICED STATED THERE WAS A POSSIBILITY OF THE BRAKES STICKING, BURNING AND THE ABS LIGHT ILLUMINATING. IT FURTHER STATED THAT IF THE SYMPTOMS SHOULD APPEAR, THAT THE DRIVER SHOULD PULL OVER AND EXAMINE THE WHEELS FOR EXCESSIVE HEAT AND CONTACT A WORKHORSE SERVICE CENTER. IN JUNE 2009 THE CONSUMER WAS ABOUT 100 MILES INTO HIS TRIP, WHEN HE EXPERIENCED OVER HEATING OF THE BRAKES AND THE ABS LIGHT ILLUMINATED. HE PULLED OVER AND CALLED THE NUMBER LISTED ON THE RECALL. ARRANGEMENTS WERE MADE TO HAVE THE RV TOWED TO A SERVICE CENTER, THE SERVICE CENTER MADE TEMPORARY REPAIRS TO THE RV AND FOUND THERE WAS ALSO A RECALL ON THE CATALYTIC CONVERTER, WHICH WAS ALSO REPLACED. IN JANUARY 2010, THE CONSUMER BEGAN TO NOTICE A SLIGHT LOSS OF POWER AND HE COULD HEAR A MUFFLED SOUND OF BACK FIRING THROUGH THE EXHAUST WHENEVER HE DROVE UP AN UPGRADE AND/OR HARD ACCELERATING. IN JUNE OF 2010, HE RETURNED THE RV TO THE SERVICE CENTER, TO HAVE THEM CHECK THE BACK FIRING AND SEVERAL OTHER ITEMS THAT NEEDED TO BE REPAIRED OR REPLACED, BUT THEY WERE UNABLE TO FIND A PROBLEM. IN OCTOBER 2011, THE RV BEGAN TO SLOW DOWN AND SMOKE STARTED EMITTING OUT OF THE LEFT EXHAUST. THE RV WAS TOWED TO A SERVICE CENTER. A DIAGNOSTIC TEST REVEALED THE CATALYTIC CONVERTERS WERE CLOGGED UP AND BLEW OUT THE MUFFLERS. THE SERVICE CENTER ALSO FOUND THE SPARK PLUGS NEEDED TO BE REPLACED. THE CONSUMER ALSO STATED OVER THE LAST FIVE YEARS, THE FUEL PUMP, SERPENTINE BELT, HEATER VALVE, SPEEDOMETER, DASH PANEL CLUSTER LIGHTS AND TURN SIGNAL/ DIMMER SWITCH ALL HAD TO BE REPLACED.
NHTSA complaint #10440813 — an unverified report by a vehicle owner.
Laytonville, CA
SERVICE BRAKES, HYDRAULIC
2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES TO INQUIRE ABOUT RECALLS *TGW THE CONSUMER STATED THE ANTI-LOCK BRAKE LIGHT ILLUMINATED TWICE AND THE REPAIR SHOP REPLACED THE WHEEL SENSORS. ALSO, THE FRONT BRAKE PADS AND ROTORS WERE REPLACED. THE CONSUMER STATED HE RECEIVED A PENDING RECALL NOTICE FOR THE BRAKES. HE CONTACTED THE DEALER TO MAKE AN APPOINTMENT, BUT WAS INFORMED IT WOULD BE MONTHS BEFORE THE REPAIRS COULD BE MADE.
NHTSA complaint #10403448 — an unverified report by a vehicle owner.
Altoona, PA
SERVICE BRAKES, HYDRAULIC
2003 WORKHORSE HORSE CHASSIS. CONSUMER WRITES IN RESPONSE TO A DENIAL OF REIMBURSEMENT FOR REPLACEMENT OF CALIPER ASSEMBLY. *TGW THE CONSUMER STATED ALL OF THE REPAIRS MADE FROM SEPT 2007 THROUGH JULY 2008 PRIOR TO AN SAFETY RECALL NOTICES FROM WORKHORSE. ON SEPTEMBER 12, 2007, BOTH FRONT WHEEL SEALS WERE LEAKING AND HAD TO BE REPLACED. WORKHORSE DENIED THE CLAIM, BECAUSE THEY WERE ONLY CONSIDERING REPAIRS MADE AFTER NOVEMBER 16, 2007 FOR REIMBURSEMENT. ON A SEPARATE OCCASION, WHILE ENROUTE TO HIS SUMMER HOME, THERE WAS A BURNING ODOR AND SMOKE COMING FROM THE WHEEL. THE MECHANIC REMOVED THE BURNED ABS SENSOR AND REPLACED THE HUB CAPS AND SEALS.
NHTSA complaint #10403092 — an unverified report by a vehicle owner.
Birmingham, AL
SERVICE BRAKES, HYDRAULIC
2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES REGARDING WORKHORSE WARRANTY AND SAFETY RECALL *TGW THE CONSUMER EXPERIENCED BRAKE PROBLEMS WHILE ON A TRIP. THE CONSUMER WAS INFORMED BY THREE DEALERS THAT IT WOULD BE SEVERAL WEEKS BEFORE HE COULD RECEIVE SERVICE. THE CONSUMER FINALLY FOUND A SERVICE CENTER AND MADE AN APPOINTMENT FOR THE FOLLOWING WEEK. THE CONSUMER BELIEVED HE WAS CHARGED FOR REPAIRS THAT SHOULD HAVE BEEN COVERED IN THE RECALL. HE LEARNED THE PROBLEM WITH THE ABS AND EMERGENCY BRAKE LIGHTS WAS A PROBLEM THAT OCCASIONALLY OCCURRED WHEN THE RECALL WORK WAS PERFORMED. THE CONSUMER IS REQUESTING REIMBURSEMENT FOR THE ABS, EMERGENCY BRAKE LIGHTS AND BUZZER NOT GOING OUT.
NHTSA complaint #10389488 — an unverified report by a vehicle owner.
Houston, TX
SERVICE BRAKES, HYDRAULIC
2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES IN REGARDS TO BAD BRAKES *TGW THE CONSUMER STATED HE/SHE FIRST EXPERIENCED FRONT BRAKE FAILURE IN SEPT 2007. THE FRONT BRAKES LOCKED UP WHICH CAUSED THE BRAKES TO OVERHEAT. THE FRONT CALIPERS, BRAKE PADS, FRONT INNER SEALS, FRONT OUTER HUB COVERS AND ROTORS HAD TO BE REPLACED. ALSO, THE RIGHT FRONT WHEEL SPEED SENSOR WAS DEFECTIVE AND HAD TO BE REPLACED AS WELL . THE SECOND TIME WAS IN APRIL 2008 WHEN THE REAR CALIPERS SEIZED AND DAMAGED THE ROTORS AND PADS. THE BRAKES WERE REPLACED UNDER AN EXTENDED WARRANTY. THE CONSUMER STATED HE/SHE RECEIVED A REFUND CHECK FOR THE REAR BRAKES ONLY. THE CONSUMER STATED SINCE A RECALL WAS ISSUED, ALL OF HIS/HER MONEY SHOULD BE REFUNDED INCLUDING MONEY FOR THE COMPONENTS THAT WERE DAMAGE AS A RESULT OF THE FAILED BRAKES.
NHTSA complaint #10389288 — an unverified report by a vehicle owner.
at 37,500 milesSAN Leon, TX
SERVICE BRAKES, HYDRAULIC
SAFETY RECALL 51101-C. BRAKE CALIPERS FAILED AND BURNED UP THE ENTIRE BRAKING AND ABS SYSTEM. WORKHORSE IS REFUSING TO PAY $4,600 CASH I PAID TO REPAIR THE DAMAGE
NHTSA complaint #10383849 — an unverified report by a vehicle owner.
at 24,000 milesLiberty Township, OH
ELECTRICAL SYSTEM
TL*THE CONTACT OWNS A 2003 ALEGRO RECREATIONAL VEHICLE WITH A WORKHORSE W22 CHASSIS. THE LIQUID SCREEN CRYSTAL DISPLAY FAILED, HE WAS NOT ABLE TO READ THE MILEAGE, SPEED, GEAR, OR ANY OTHER INFORMATION ON THE SCREEN. THE RECREATIONAL VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 24,000 AND THE CURRENT MILEAGE WAS 28,669.
NHTSA complaint #10378810 — an unverified report by a vehicle owner.
Jacksonville, FL
SERVICE BRAKES, HYDRAULIC
CONSUMER WRITES IN REGARDS TO SAFETY RECALL 51101-C WORKHORSE CUSTOM CHASSIS BOSCH BRAKE CALIPER *TGW THE CONSUMER STATED WHEN HE APPLIED THE BRAKE GENTLY TO STOP FOR TRAFFIC, THE RIGHT FRONT BRAKE LOCKED UP AND WOULD NOT RELEASE. HE DROVE SLOWLY ALMOST AT FULL THROTTLE TO THE CAMPGROUND WITH SMOKE EMITTING FROM THE WHEEL BEARING. THE BRAKE ROTOR, CALIPER AND ABS SENSOR HAD TO BE REPLACED. WORKHORSE STATED THE CONSUMER WAS NOT ELIGIBLE FOR REIMBURSEMENT AS THE REPAIRS WERE NOT MADE BETWEEN NOVEMBER 16, 2007 AND JUNE 15, 2009.
NHTSA complaint #10375901 — an unverified report by a vehicle owner.
Phoenix, AZ
SERVICE BRAKES, HYDRAULIC
2003 RV. ATTORNEY WRITES ON BEHALF OF CONSUMERS REGARDING FAULTY BRAKES AND RECALL. *TGW AN INSPECTION OF THE RV REVEALED EXTREME CRACKING DAMAGE HAD BEEN CAUSED TO THE ROTORS WHICH WAS A DIRECT RESULT OF THE FAULTY BRAKE CALIPERS. THE CONSUMER WAS INFORMED THAT THE RECALL DID NOT COVER ADDITIONAL DAMAGE THAT HAD BEEN CAUSED TO THE ROTORS BY THE FAULTY CALIPERS. THE CONSUMER HAD TO PAY FOR THE ROTORS, PADS AND BRAKE LINES. ALSO, THE ABS WAS SERVICED TWICE PRIOR TO THE RECALL.
NHTSA complaint #10375899 — an unverified report by a vehicle owner.
at 50,983 milesPalmyra, NY
SERVICE BRAKES, HYDRAULIC
TL* THE CONTACT OWNS A 2003 WORKHORSE W22. THE CONTACT STATED THAT THE VEHICLE WAS BEING SERVICED FOR REPAIRS UNDER NHTSA CAMPAIGN ID NUMBER: 09V110000 (SERVICE BRAKES, HYDRAULIC) WHEN HE WAS INFORMED BY THE TECHNICIAN THAT ALL FOUR ROTORS WERE FRACTURED AND THE VEHICLE WAS DEEMED AS UNSAFE TO DRIVE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND ADVISED THE CONTACT THAT THE FAILURE WAS COMMON AND THEY WERE UNABLE TO PROVIDE ANY ASSISTANCE. THE APPROXIMATE FAILURE MILEAGE WAS 50,983. UPDATED 03/15/11 *BF UPDATED 06/03/11
NHTSA complaint #10376714 — an unverified report by a vehicle owner.
at 42,000 milesCape Coral, FL
SERVICE BRAKES, HYDRAULIC
TL*THE CONTACT OWNS A 2003 WORKHORSE W-22. THE CONTACT STATED THAT HE RECEIVED A RECALL NOTICE FOR RECALL 09V110000 (SERVICE BRAKES, HYDRAULIC). THE VEHICLE WAS REPAIRED ACCORDING TO THE RECALL AND THE CONTACT WAS INFORMED THAT THE ROTORS HAD CRACKED DUE TO THE HEAT GENERATED FROM THE FAILED CALIPERS. THE DEALER STATED THAT EVEN THOUGH THE ROTORS WERE A PART OF THE BRAKING SYSTEM, THEY WOULD NOT BE REPAIRED UNDER THE RECALL. THE FAILURE MILEAGE WAS 42,000.
NHTSA complaint #10376408 — an unverified report by a vehicle owner.
Birmingham, AL
SERVICE BRAKES, HYDRAULIC
CONSUMER WRITES REGARDING SAFETY RECALL 51101-C INVOLVING THE BOSCH SERVICE BRAKE CALIPER *TGW THE CONSUMER EXPERIENCED PROBLEMS WITH THE BRAKES WHILE ON A TRIP. WHEN THE CONSUMER ARRIVED AT THE DEALER, HE WAS INFORMED IT WOULD BE SEVERAL WEEKS BEFORE SERVICES COULD BE PERFORMED. THE CONSUMER THEN DECIDED TO SCHEDULED AN APPOINTMENT AT ANOTHER ESTABLISHMENT. THE REPAIR WAS SHOP WAS ABLE TO FINISH THE BRAKE RECALL WORK. HOWEVER, THEY WERE UNABLE TO GET THE ABS AND EMERGENCY BRAKE LIGHT AS WELL AS THE WARNING BUZZER TO OUT. THE NEXT DAY, THE REPAIR SHOP WAS ABLE TO RECTIFY THE PROBLEM. THE CONSUMER WAS CHARGE FOR THAT REPAIR. THE CONSUMER BELIEVED IT SHOULD HAVE BEEN COVERED UNDER THE RECALL AS WELL.
NHTSA complaint #10372792 — an unverified report by a vehicle owner.
Lacey, WA
SERVICE BRAKES, HYDRAULIC
2003 W-22 WORKHORSE CHASSIS MOTOR HOME. CONSUMER STATES THAT HE HAD A RECALL FOR THE BRAKES AND ENDING UP PAYING FOR THE REPAIR. HE FEELS THAT WORKHORSE SHOULD HAVE PAID SINCE THE PART WAS UNDER RECALL. *KB THE CONSUMER STATED THE ABS LIGHT ILLUMINATED. THE RV WAS TAKEN TO A REPAIR SHOP AND THEY TURNED THE LIGHT OFF AND ADVISED THE CONSUMER TO COME BACK IN A FEW DAYS FOR A FULL INSPECTION. THE CONSUMER RETURNED A FEW DAYS LATER FOR A REAR BRAKE INSPECTION. THE REPAIR SHOP INFORMED THE CONSUMER THE REAR BRAKES HAD BECOME VERY HOT AND BURNED AND WOULD NEED TO BE REPLACED. WHEN THE PARTS ARRIVED, THE CONSUMER WENT BACK TO THE SHOP TO HAVE THE REAR BRAKES REPLACED. TWO YEARS AFTER HAVING THE REAR BRAKES REPLACED, THE ABS LIGHT ILLUMINATED AGAIN AND THE CONSUMER BEGAN HEARING STRANGE SOUNDS AND THE RV DROVE A LITTLE DIFFERENTLY. WHEN THE CONSUMER WAS ABLE TO PULL OVER, HE LOOKED UNDER THE RV AND SMELLED A STRANGE ODOR AND THE BRAKES WERE EXTREMELY HOT. THE CONSUMER WAS ABLE TO SAFELY DRIVE THE RV TO A REPAIR SHOP, ONCE THE BRAKES COOLED DOWN. THE REPAIR SHOP DETERMINED THE FRONT BRAKES HAD SEIZED AND OVERHEATED AND NEEDED TO BE REPLACED. THREE MONTHS LATER, THE CALIPERS WERE REPLACED.
NHTSA complaint #10370010 — an unverified report by a vehicle owner.
Falconer, NY
SERVICE BRAKES, HYDRAULIC
2003 WORKHORSE CHASSIS. COURTESY COPY OF A LETTER FROM JAMES M. WALKER SUBMITTED TO WORKHORSE CUSTOM CHASSIS RE RECALL CAMPAIGN NUMBER 51101 *TGW THE CONSUMER STATED THE RECALL WORK PERFORMED. THE DEALER REPLACED THE FAULTY CALIPERS AT NO CHARGE, BUT FOUND TWO ROTORS CRACKED BEYOND REPAIR AND TWO OF THEM REQUIRED RESURFACING, ALL DUE TO HEAT PROBLEMS CAUSED BY THE FAULTY CALIPERS. THE CONSUMER IS REQUESTING REIMBURSEMENT FOR THE DAMAGED ROTORS. IN AUGUST 2005 ALL FOUR ROTORS HAD TO BE REPLACED DUE TO HEAT RELATED PROBLEMS CAUSED BY FAULTY CALIPERS. THE PADS WERE ROUTINE MAINTENANCE, BUT THE SEALS FAILED AND WERE SUBSEQUENTLY REPLACED. THE CONSUMER IS ALSO REQUESTING REIMBURSEMENT FOR THOSE ROTORS.
NHTSA complaint #10370018 — an unverified report by a vehicle owner.
Corvallis, OR
SERVICE BRAKES, HYDRAULIC
2003 W22 WORKHORSE CHASSIS. CONSUMER WRITES TO REQUEST A WORKHORSE REIMBURSEMENT *TGW THE CONSUMER IS REQUESTING REIMBURSEMENT AS A RESULT OF HAVING THE CALIPERS REPLACED. THE REPAIR FACILITY RECOMMENDED THE REPLACEMENT OF THREE ROTORS WHICH WERE CRACKED. THE CONSUMER STATED THERE WAS A DISTINCT BRAKE BURNING SMELL, THE ABS LIGHT ILLUMINATED FOR EXTENDED PERIODS OF TIME, AND THERE WERE AT LEAST THREE TIMES THE BRAKING SYSTEM LOST ITS EFFECTIVENESS.
NHTSA complaint #10368981 — an unverified report by a vehicle owner.
Montgomery, AL
SERVICE BRAKES, HYDRAULIC
2003 WORKHORSE W22 CHASSIS. CONSUMER WRITES TO SEEK AN EXPLANATION AS TO WHY THE RECALL DID NOT COVER THE REPLACEMENT OF THE LEFT FRONT AND LEFT REAR ROTOR, PADS, OIL SEAL AND SPEED SENSOR *TGW THE CONSUMER STATED THE RIGHT FRONT SIDE OF THE RV WAS COVERED UNDER RECALL, BUT NOT THE LEFT SIDE.
NHTSA complaint #10367509 — an unverified report by a vehicle owner.
Miami, FL
SERVICE BRAKES, HYDRAULIC
CONSUMER WRITES REGARDING WORKHORSE RECALL *TGW THE CONSUMER WAS DENIED REIMBURSEMENT. ACCORDING TO WORKHORSE, THE WORK INVOICE DID NOT REFERENCE A PROBLEM CONCERNING CALIPER FAILURE AND THEY FURTHER STATED THE CONSUMER DID NOT TAKE THE RV TO AN AUTHORIZED SERVICE CENTER FOR THE BRAKE FAILURE. THE CONSUMER STATED THE BRAKE SYSTEM LOCKED UP COMPLETELY AND BEGAN SMOKING PROFUSELY WHILE THE RV WAS BEING DRIVEN DURING RUSH HOUR TRAFFIC. THE BRAKE DISCS WERE SEVERELY WARPED AND THE CALIPERS WERE COMPLETELY INOPERATIVE. *JB UPDATED 01/05/11. *JB UPDATED 01/13/11.
NHTSA complaint #10366292 — an unverified report by a vehicle owner.