I’m concerned about the caliper fix.

Full-Timers · 01-25-2010, 08:16 PM

I am concerned that this caliper replacement will not fix the Workhorse brake problem. There have been many attempts to fix this problem in the last 5+ years such as changing to a different style and/or lubing the guide pins, adding a zerk fitting and lubing the brake shaft, and now replacing the calipers. The real reason I am concerned is because some have reported replacing the calipers and still experienced a lockup, some multiple times. Also this problem seems to be concentrated to the Workhorse W22 chassis. There are lots of other vehicles using the same calipers that have not seen as many brake problems as the Workhorse W22 chassis. I sure hope there’s not going to be a lot of money spent just to find out there is still a problem.

DriVer · 01-25-2010, 08:54 PM

Quote:

Originally Posted by Full-Timers

I sure hope there’s not going to be a lot of money spent just to find out there is still a problem.

I am also of the same opinion. I hope that Bosch gets it right and I do expect that Workhorse will hold them to their promise of providing owners with calipers that will work well for the long run. Once we get the recall behind us all we need to do is our part to keep everything working properly. I'm sure that we have all grown in maturity and that we'll be looking at spending a small amount on maintenance to keep from spending a big amount on repairs.

wa8yxm · 01-26-2010, 09:27 AM

There are 3 problems with workhorse brakes.. One of them the caliper replacement (NOT a "Fix" but an entire new assembly) WILL beyond a doubt fix.. The problem is the materials and specifications of the original caliper simply did not work out. The new unit has different material in the piston and different specifications (Same stopping power though) and thus WILL work.

The next problem is one that a Ford Chassis owner recently expierenced and I had on my towed (Also not a workhorse) it can strike any vehicle with hydraulic brakes.. I won't go into it since it can strike ANY vehicle with hydraulic brakes.. (Brake line failure)

The finaly one is the bell crank. Early (Prior to 2005) WH units the bell crank did not have a ZERK fitting, Either mid year 2004 or mid-year 2005 (I do forget which) They added one... Use of the proper (Lithium) grease keeps it cranking freely.. I need to lube mine later this week. Also you may need to push the rubber boot INSIDE the coach toward the firwall a bit to insure the pedal returns FULLY to the released position.

Thankfully my grease gun is full of Lithium

jdsr · 01-26-2010, 10:58 AM

Unless I read it wrong the new caliper piston will be made from the same material. The only change I could see is the bore will be slightly bigger. Im not a big fan of them saying the only change they are making in the new calipers is the bore size. As far as zerk fitting. I had 2 installed in early 2004 prior to any of my 3 brake failures, didnt help me. But its just my opinion.

Davel · 01-26-2010, 11:12 AM

jdsr,

The new piston will still have phenolic in it as it the best way to insulate the brake fluid during braking. We were told in Tampa that the piston had been redesigned and that the tolerances also would be changed to open up or prevent clearances that are on the "tight" side.

Dave

jdsr · 01-26-2010, 11:56 AM

Thats what I understood as well except I didnt read about the redesign of the piston. I will reread on how or why the piston was redesigned.

DriVer · 01-26-2010, 02:30 PM

Quote:

Originally Posted by Davel

.... the piston had been redesigned and that the tolerances also would be changed to open up or prevent clearances that are on the "tight" side.

Dave, Although I wasn't there, what was told to the Club members in Greenville was that in a forensic study, it was discovered that some pistons were manufactured "tight" while others were OK and didn't present any problems. I expect this is what you all heard back then.

From that testimony and from what you have recently been told in person as of December 09 about the pistons, I expect that the fix will be successful because they know what the mechanism of failure is. Just as in any disaster whether its solid rocket boosters or airline fuel tanks once you know what the problem is, it can be fixed.

Full-Timers · 01-26-2010, 05:04 PM

Quote:

Originally Posted by DriVer

I expect that the fix will be successful because they know what the mechanism of failure is. Just as in any disaster whether its solid rocket boosters or airline fuel tanks once you know what the problem is, it can be fixed.

Well all I am saying is, they new what the problem was when they issued the guide pin recall and they new what the problem was when they added the zerk. Now they know what the problem is when they redesign the calipers….

max49 · 01-26-2010, 06:27 PM

I would think a smaller piston or larger bore would fix it. No body else that I'm aware of has this many brake problems.
What I don't understand is "What is taking so long ?"
I don't mean to steal a line from Driver but "Just getter done"

I think I misspelled that, tho.

Full-Timers · 01-26-2010, 07:45 PM

There has to be other vehicles out there with these same calipers. Bosch didn’t just make these calipers for the Workhorse chassis. Why aren’t we seeing as many problems reported with those vehicles? Is it not the calipers at fault?
Anyone?
Anyone?

max49 · 01-26-2010, 08:08 PM

Full Timers, unfortunately you may have answered the question as to why it's taking so long.
Does Bosch build the entire brake system? Master cylinder, booster, brake lines , ABS sensors and all the other parts of the system? Maybe, they're looking to place responsibility else where.

dieselclacker · 01-26-2010, 08:10 PM

I wonder what the percentage figure is of motorhome owners who have had caliper siezure, versus motorhome owners who have had no siezures.

Could the GVW of motorhomes, compared to the GVW of other vehicles equipped with Bosch 66 mm calipers, have anything to do with them seemingly to not have as many brake caliper problems as the motorhome owners?

I am at 37 thousand miles on our 2003 W-22 chassis, and have as yet had no brake problems.

Dieselclacker

max49 · 01-26-2010, 08:22 PM

On edit,
Workhorse chose who they bought the parts from , so it seems to me, they are responsible. But when you go deeper, Winnebago, Damon, Tiffin , Newmar etc have their name all over it, and they chose where they bought their chassis from , so I don't understand how they get a pass to get out of jail free either.
That's probably why we don't see too many MHs on the showroom on the WH chassis any more. If WH can survive this and thrive again they will have proven that they are an amazing company, IMO of course