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Bosch 51101-C Brake Caliper Recall - Done !

Posted 09-09-2010 at 09:28 PM by DriVer
Updated 10-23-2010 at 05:17 PM by DriVer

I found out through the grapevine that my service center was about to receive a number of the new Bosch Brake Calipers, so I called them and made an appointment. Wanting to clear the campaign early, Larry gave me the first available spot he had for Wednesday morning at 08:00.

Wednesday morning came not all too quickly but here we are. The motorhome was all ready to go and with crank of the starter the engine fired up and we were on the road to Myrtle Beach. I turned the radio on and sat back and enjoyed the 15 or so mile run out to Northgate Boulevard.


Brand New Bosch 29502B 2x66mm Hydraulic Calipers

The way we came in off of Route 544 Northbound requires you to make a right hand 180° turn and an immediate left, Larry’s is right at the end of the street. One of the guys saw me coming and moved a car on the ramp and gestured that I should approach him. I was parked as most people are on the front apron.

I got out and chewed the fat for a few minutes before they got organized and started getting on my vehicle. Larry hired a helper who jacks up the vehicle and takes off the tires. Of course in my case they placed some blocks under my jacks and I was able to assist in lowering the jacks and raising the vehicle tires off the ground. It was quite easy to do with the hydraulic jacks.



Bosch Caliper casting number 4153269. Production number 0225C = Made in 2010 on day 225 by shift C.

Next came out the impact guns, the wheel covers were removed and the tires came off. The helper that began work on my vehicle was initially struggling with my Crossfires but he quickly got that under control. Here come the new calipers, one was placed in the vicinity of each of the wheel openings.

When all the rubber was clear, David my tech for this repair came out and began to disassemble the rear calipers. What was found surprised me because it was like Déjà Vu all over again, like Yogi would have said. When we pulled the rear calipers off the brake pads were worn approximately 50% of the way. Essentially you could see that the lining was a little thicker than the pad back plate and this typically is a sign that the pads need to be replaced however on BIG brakes like this I could have gone a few more thousand miles but why bother, I opted to get a new pair of pads. After all I’m here and the wheels are off at this point.



The inside of the pistons are stamped with a "B". This stamp identifies the new piston material.

OK so what’s so unusual? In July 2008 I had all my brake components replaced by Larry’s at some 65,000 miles. I previously wrote that I had worn my pads down to the point where the back plate was chewing up the rotor. Not a very good scenario at all. At that time I went for calipers, pads and rotors. Today we see where the back pads are worn down ~45% in some 21,000 miles and 2 years. The rotors on the drive axle were both perfect. Now here’s where the other shoe drops.

Curious I inspected the front brake pads and they show no appreciable wear at all. Perhaps 10% - 15% if that was all that they were worn. In my school, I was taught that the weight of a vehicle transfers to the front axle and that the lion’s share of the braking was accomplished by the steer axle. In any of the cars I have had with disk brakes, I have had to replace the front pads and rotors while still running the same stuff on the rear axle. So it’s like a small mystery to me but now that I have seen a pattern, I can anticipate when my brake pads are going to need to be inspected and or possibly replaced.



The lining material was almost as thick as the backplate. I chose to replace the rear pads with new ones.

On the rear calipers both the leading and trailing pins were removed and the caliper set aside. A new set of semi-metallic brake pads were installed on the drive axle along with the new calipers. The rotors were smooth and we elected to leave them alone. The pins were coated with the appropriate lubricant and new pad slippers were installed on the anchor plate. The pins boots in all cases were retained. The brake pads were put in place. The stock bleeders were removed and I provided a set of 4 of Oemy’s Speed Bleeders which were each threaded into the bleeder ports. The calipers were installed on the trailing pin first and rotated up and the leading pin was installed and secured. David just got this new long handle Matco ratcheting wrench. He said it was the best tool that he’s gotten to work on the brakes. He didn’t bother getting the whole set, just that one sized wrench is all he wanted. The pins were ratcheted up and tightened. The brake line was brought over from the old caliper and installed on the new. The ABS sensors were not serviced.


New pad and caliper. The rotors were all fine without any stress cracks.

The opposite wheel was serviced in the same manner and again the lining on the pad exhibited some appreciable wear.

Moving up to the front wheels, the old calipers were removed and the new calipers were installed and that was it. David brought his hand operated vacuum pump and inserted the hose into the master cylinder reservoir and started removing brake fluid. The attached bottle was 16 ounces and 2 bottles of fluid were removed from the Hydro-Max. David said that although most of the fluid comes out from either hole he pumps out both just to make sure he gets it all. While the fluid was being withdrawn I noticed how clean my fluid was since I had just recently flushed it. 2 Quarts of DOT3 were brought over and one was immediately poured into the master cylinder reservoir.


Front pads were retained. Seen with old calipers. (Steer axle)

When we were ready, I sat in the seat, started the engine and pumped the pedal to bleed out the calipers. That went by quickly with but a few pumps at each wheel. The master cylinder reservoir was topped off and the caps were secured. Once the tires were but back on the motorhome, the Crossfires were put back on. The tire pressure was checked and adjusted because the tires will leak down when the Crossfires are removed. Bringing up the pressure to the Crossfire’s 90 PSI rating, the cross hairs line up on the center of the sight gauge. Done.


Campaign Sticker is fitted to officially complete the recall.

The vehicle was lowered and was taken out for a test drive. All set and ready to go in approximately 3.0 Hrs.


Final checks and ready to roll!

The Service Center is:

Larry's Auto Clinic
4719 Northgate Boulevard
Myrtle Beach, SC 29577-6696
(843) 293-2205
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Comments

  1. Old Comment
    Good report, thanks for the info and pictures and for all that you contribute to this site.
    Posted 09-10-2010 at 07:40 AM by RIDE10 RIDE10 is offline
  2. Old Comment
    Whaler's Avatar
    Hi Mike! Have you looked into why the rear brakes are wearing so fast?
    Gene
    Posted 09-10-2010 at 01:45 PM by Whaler Whaler is offline
  3. Old Comment
    Driver, I have the exact same Adventurer and have been waiting for info on the Bosch Recall, but have heard nothing. Is there something on the street? I am anxious to get it done as I had a total brake failure on a trip in Birmingham, AL
    Posted 09-16-2010 at 02:12 PM by Adventurer03 Adventurer03 is offline
  4. Old Comment
    Have you had any other problems with your Adventurer. I had to have the speedometer unit replaced as I could no longer read any of the digital information. luckly my RV technician knew there was a recall and was able to assist and get it done under warranty
    Posted 09-16-2010 at 02:14 PM by Adventurer03 Adventurer03 is offline
  5. Old Comment
    DriVer's Avatar
    Workhorse has put forward a voluntary recall 51101-C. The letters to the owners are imminent and should be in your mailbox before the end of the month.

    If you have a brake problem right now, go to the Workhorse Service Center and they should be able to take care of the problem.

    Remember there is no charge to have all 4 calipers replaced.
    Posted 09-16-2010 at 02:17 PM by DriVer DriVer is offline
  6. Old Comment
    DriVer's Avatar
    Quote:
    Originally Posted by Adventurer03 View Comment
    Have you had any other problems with your Adventurer. I had to have the speedometer unit replaced as I could no longer read any of the digital information.
    Yes sir, I had my speedometer replaced back in 2006 I believe. It's been fine ever since.
    Posted 09-16-2010 at 02:19 PM by DriVer DriVer is offline
  7. Old Comment
    Wanabee FTer's Avatar
    Mike,
    It is possible the rear brake pads are designed to wear out before front pads, it depends on the design of the brake proportioning valve and the composition of the rear brake pad material. My example would be 1998 and newer Honda Accord's. Honda designed the rear brake pads with a softer composition to achieve the desired braking results. The softer pads gave the vehicle a much better panic stop rate. Only problem was, customers were always complaining that there was something wrong with their brakes. Most people believe you should get twice the pad life for front brakes, but with the Accord example, rear brakes wore out twice as fast as front brakes did.
    Posted 10-30-2010 at 08:55 PM by Wanabee FTer Wanabee FTer is offline
  8. Old Comment
    Just had my 51101-c done 12-6-10 in Yuma. Sure wish I had your luck and contacts. 2 front rotors (out of stock for rear) 4 sets pads $1240.00 $900 more to do 2 rear rotors when they arrive. rear pads were still 90% inner 85% outer front 75% inner 40% outer. I question the need for rear rotors as I use brakes to stop and all other speed control is with gears. 40155 miles on "04" 32' Sea Breeze LX W22. I have old parts and Pix. Is this WRONG or what
    Posted 12-09-2010 at 06:44 PM by rvrovers rvrovers is offline
  9. Old Comment
    DriVer's Avatar
    Quote:
    Originally Posted by rvrovers View Comment
    Just had my 51101-c done 12-6-10 in Yuma. Sure wish I had your luck and contacts. 2 front rotors (out of stock for rear) 4 sets pads $1240.00 $900 more to do 2 rear rotors when they arrive. Is this WRONG or what
    I don't know what the problem was in getting the rotors, both the front and rear rotors are the same. To completely rebuild your brakes, if you had chosen a "Select Service Center" it would have cost you $1499.00 out the door complete. This would have been, 4 calipers, 4 rotors, 4 set of pads, fluids, seals, labor AND taxes.
    Posted 12-12-2010 at 07:47 PM by DriVer DriVer is offline
 
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