Major brake caliper failure in both front wheels

[georgem37303]

This morning we left our home in Athens,tn, and headed for Florida. After about 25 miles traveling south on I 75, the ABS light came on the dash. Soon after that the smell of brake pads. At this point I pulled over to see if I could see any problems. Not seeing any, I proceeded on to Florida. About 10 more miles down the road, my air pressure sensor on the right front tire sounded. I pulled over and found that the tire was indeed going flat. But, more surprising was that there was oil all around the tire, dripping our from the bottom of the wheel cover and all over the wheel well and side of the coach. The reason I found for the tire going flat was that the wheel had gotten so hot that it melted the pressure sensor on the valve stem and allowed the air to escape. Then just on a hunch I went around to the drivers side and found that the same oil was all over tire and side of the coach. At this point we decided to turn around and go home. Upon arriving home I removed the wheel covers and couldn't believe what I saw. both sight glasses for the wheel bearing oil had melted and allowed all the oil to pour out. Now, there's no telling how long the bearings had run dry.

Monday morning I am calling the service center in Chattanooga who worked on the coach last November for a rear wheel caliper replacement. I will be advising them that I will be heading their way in the next day or so. I will also be letting them know that I am not taking any crap from Workhorse. I want both wheels completely replaced. Calipers, rotors, wheel bearings sight glass, and possibly new tires which were replaced 800 miles ago. I really question the integrity of the tire if it got as hot as the wheel did to melt the pressure sensor.

Should Workhorse not repair my coach to my satisfaction, I promise everyone reading this, I will file a civil action in county court for the cost of all the necessary repairs to make me happy. We have a very nice historic courthouse in downtown Athens, and I'm sure their attorney will enjoy seeing it on his way into the courtroom to attempt to defend Workhorse on this whole issue of brake failures. Five years is enough time to correct the problem. I will be on a very short fuse when I arrive at the dealership. I will keep you updated on my success.

[DriVer]

Quote:

Originally Posted by georgem37303 This morning we left our home in Athens,tn, and headed for Florida. After about 25 miles traveling south on I 75, the ABS light came on the dash. Soon after that the smell of brake pads..

georgem37303, May we please know your year, make and model, chassis type and mileage. That data is absent in your post. Thanks.

I would hope that you have called Workhorse Roadside Assistance and create a peper trail before you go to the dealer. 877-946-7731.

[thepratts]

Did you get the pre-recall letter from Workhorse? It specifically says to stop and let your brakes cool for about 45 minutes if the ABS light comes on.

I have had two brakes fail due to dragging. After cooling down they were OK to drive again. Both times the ABS light came on (melted ABS sensor). On my front wheel I did have a problem with the oil coming out. But I think it was the inside seal, not melted plastic. Put in some synthetic gear oil and it has been OK.

Everyone, be very cautious if you have an ABS light come on. It usually means you have a dragging brake and it has melted the sensor. It MAY correct itself after a cooling period.

[georgem37303]

DriVer
I own a 2004, 35 foot Dolphin LX. Its on a W22 workhorse chassis. The mileage is 36,860. Yes, I have contacted Workhorse and it appears they are going to have it towed from my home in Athens, to Lee Smith in Chattanooga. This is where I had the right rear wheel caliper and rotor repaired by Workhorse back in November.

Had my air pressure sensor not melted and started loosing air, I hate to think what might have happened when the dry wheel bearings would have failed.

Just a question. Will Workhorse reimburse me for the cost of replacing the valve stem air pressure sensor? I am taking with me to Lee Smith so they can see it. Also when I spoke to Dennis at the service center, he said melting wheel bearing sight glass is common when the front wheel calipers malfunction. Another question I have is, to me if the wheel was hot enough to melt the plastic, what condition are the brake pads in? I think they should be replaced, IMO.

[darbyjudy]

George I am sorry you are having these problems and I hope Workhorse doesn't give you a bunch of crap. I agree with you this has gone on long enough. Every time I read this forum there is another failed brake. I have went through the same problems and Workhorse requires that you jump through the hoops and roll over before you get any thing done. The last time before they would fix mine I had to agree to flush the brake fluid to the tune of $300 before they would repair. Even though we all know that the calipers locking up would burn the brake fluid and make it to where it needs replaced. Workhorse is walking a fine line, they are so lucky that no one has been killed or badly injured because of this problem, but they still are in no hurry to get the job done. What are they waiting for all of us to die.

[georgem37303]

darbyjudy
Last July I had the brake fluid flushed. I wonder what the high heat did to my fresh fluid? I just hope Workhorse will replace it. I am waiting now for the tow company to call and get the coach for a ride to the service center. I will keep everyone posted on the outcome.

[jdsr]

Quote:

Originally Posted by georgem37303 darbyjudy Last July I had the brake fluid flushed. I wonder what the high heat did to my fresh fluid? I just hope Workhorse will replace it. I am waiting now for the tow company to call and get the coach for a ride to the service center. I will keep everyone posted on the outcome.

If your fluid boiled it is probly toast. As most of us have figured out, rpl brake fluid, just to replace will not prevent or cure our brake problems. Its easy to do and not expensive so it cant hurt. This has been my experiance on my mh and "every" mech I have talked to agrees, and I have talked to alot of them. Good luck with wh

[darbyjudy]

Yes I am sure the brake fluid is toast now. I just flushed mine last week in preparation for my trip. I had it replaced last August and it had started to change color a little but was not that bad. I guess I am now gun shy and I am trying to to everything possible so that I won't have problems on the trip to TN. I am even routing myself a way so I don't have to stop that much. But as we all know they are times we must push on the brake pedal. My brake problems has always happened when ever I get into an area where I have to do a lot of stopping.
I keep praying that I will get the notice in the mail where Workhorse has began the recall. It certain has taken some of the fun out of it. Being 75 is enough to worry about without all these brake problems. I just mentioned to the wife that maybe we should take our losses and sell and give up this life style.
Have a great day and lets hope Workhorse doesn't give you any problems.