2003 Workhorse W22 Recalls & Complaints

Incident: October 31, 2021 · Filed: January 14, 2022

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.

Incident: July 29, 2010 · Filed: July 14, 2018

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.

Incident: June 4, 2016 · Filed: June 25, 2016

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.

Incident: June 1, 2009 · Filed: December 22, 2011

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. *JB

Incident: May 6, 2011 · Filed: May 26, 2011

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. *JB

Incident: September 12, 2007 · Filed: May 24, 2011

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. *JB

Incident: March 1, 2011 · Filed: March 11, 2011

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. *JB

Incident: September 1, 2007 · Filed: March 10, 2011

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. *JB

Incident: August 10, 2010 · Filed: February 18, 2011

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

Incident: January 1, 2009 · Filed: January 26, 2011

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.