NHTSA Action Number : EA07016

[DriVer]

NHTSA Action Number : EA07016 NHTSA Recall Campaign Number : N/A
Make / Models : Model/Build Years:
WORKHORSE / W20 2000-2005
WORKHORSE / W22 2000-2005
WORKHORSE / W24 2004-2005
Manufacturer : WORKHORSE CUSTOM CHASSIS
Component : SERVICE BRAKES, HYDRAULIC
Date Investigation Opened : November 16, 2007
Date Investigation Closed : Open
Summary:

Make: WORKHORSE
Model: W22
Year: 2003
NHTSA Action Number: EA07016

Summary:
ON JUNE 25, 2007, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED OVERHEATING DISC BRAKE CALIPERS AND POOR BRAKE PERFORMANCE IN MODEL YEAR (MY) 2000-2005 WORKHORSE CHASSIS RECREATIONAL VEHICLES. TO DATE, ODI IS AWARE OF 651 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES COMBINING BOTH ODI AND WORKHORSE'S COMPLAINT POPULATION. DURING THE PE, ODI DISCOVERED THAT THE PROBLEM IS MOST PRONOUNCED ON THE W20 AND W22 CHASSIS, BOTH EQUIPPED WITH BOSCH HYDRAULIC BRAKE SYSTEMS. THE W24 CHASSIS USES A DIFFERENT BRAKE SYSTEM AND IS BEING EXAMINED AS A PEER TO THE COMPLAINT VEHICLES. ODI'S ANALYSIS OF THE WARRANTY AND COMPLAINT DATA SUPPLIED BY WORKHORSE DURING THE PE INDICATES A DRAMATIC DROP IN BRAKE RELATED COMPLAINTS ON VEHICLES BUILT AFTER MAY 2004. AT THAT TIME WORKHORSE ADDED IN PRODUCTION ZERK FITTINGS AND GREASE LUBRICATION TO THE BRAKE MASTER CYLINDER'S BELL CRANK LINKAGE. ODI IS AWARE OF 3,782 UNIQUE WARRANTY COUNTS RELATED TO THE ALLEGE DEFECT FOR THE SUBJECT POPULATION. OF THOSE CLAIMS, 88 WERE SUBMITTED ON VEHICLES PRODUCED AFTER THE MAY 2004 PRODUCTION CHANGE. DURING THE ENGINEERING ANALYSIS, ODI AND VRTC WILL CONDUCT A VEHICLE TESTING PROGRAM TO INSPECT COMPLAINT VEHICLES AND EVALUATE VARIOUS MECHANICAL FUNCTIONS OF THE VEHICLE'S BRAKE SYSTEM. ATTEMPTS WILL BE MADE TO DUPLICATE THE BRAKING PROBLEMS BEING ALLEGED AND TO DETERMINE THE ROOT CAUSE. ACCORDINGLY, THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER STUDY THE FREQUENCY AND SCOPE OF THE ALLEGED DEFECT.

And then there's the December 28, 2007 "Final Report Memorandum"� NVS-310 that was written by a number of NHTSA Engineers and a dealership technician. This document was written after the EA07016 dated November 16, 2007. I think that this document is an interesting read.

US DOT - NTHSA - FINAL REPORT: "Trip Report to Jerry Greer RV Dealership"

[DriVer]

NHTSA Action Number : EA07016 NHTSA Recall Campaign Number : N/A
Make / Models : Model/Build Years:
WORKHORSE / W20 2000-2005
WORKHORSE / W22 2000-2005
WORKHORSE / W24 2004-2005
Manufacturer : WORKHORSE CUSTOM CHASSIS
Component : SERVICE BRAKES, HYDRAULIC
Date Investigation Opened : November 16, 2007
Date Investigation Closed : Open
Summary:

Make: WORKHORSE
Model: W22
Year: 2003
NHTSA Action Number: EA07016

Summary:
ON JUNE 25, 2007, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED OVERHEATING DISC BRAKE CALIPERS AND POOR BRAKE PERFORMANCE IN MODEL YEAR (MY) 2000-2005 WORKHORSE CHASSIS RECREATIONAL VEHICLES. TO DATE, ODI IS AWARE OF 651 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES COMBINING BOTH ODI AND WORKHORSE'S COMPLAINT POPULATION. DURING THE PE, ODI DISCOVERED THAT THE PROBLEM IS MOST PRONOUNCED ON THE W20 AND W22 CHASSIS, BOTH EQUIPPED WITH BOSCH HYDRAULIC BRAKE SYSTEMS. THE W24 CHASSIS USES A DIFFERENT BRAKE SYSTEM AND IS BEING EXAMINED AS A PEER TO THE COMPLAINT VEHICLES. ODI'S ANALYSIS OF THE WARRANTY AND COMPLAINT DATA SUPPLIED BY WORKHORSE DURING THE PE INDICATES A DRAMATIC DROP IN BRAKE RELATED COMPLAINTS ON VEHICLES BUILT AFTER MAY 2004. AT THAT TIME WORKHORSE ADDED IN PRODUCTION ZERK FITTINGS AND GREASE LUBRICATION TO THE BRAKE MASTER CYLINDER'S BELL CRANK LINKAGE. ODI IS AWARE OF 3,782 UNIQUE WARRANTY COUNTS RELATED TO THE ALLEGE DEFECT FOR THE SUBJECT POPULATION. OF THOSE CLAIMS, 88 WERE SUBMITTED ON VEHICLES PRODUCED AFTER THE MAY 2004 PRODUCTION CHANGE. DURING THE ENGINEERING ANALYSIS, ODI AND VRTC WILL CONDUCT A VEHICLE TESTING PROGRAM TO INSPECT COMPLAINT VEHICLES AND EVALUATE VARIOUS MECHANICAL FUNCTIONS OF THE VEHICLE'S BRAKE SYSTEM. ATTEMPTS WILL BE MADE TO DUPLICATE THE BRAKING PROBLEMS BEING ALLEGED AND TO DETERMINE THE ROOT CAUSE. ACCORDINGLY, THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER STUDY THE FREQUENCY AND SCOPE OF THE ALLEGED DEFECT.

And then there's the December 28, 2007 "Final Report Memorandum"� NVS-310 that was written by a number of NHTSA Engineers and a dealership technician. This document was written after the EA07016 dated November 16, 2007. I think that this document is an interesting read.

US DOT - NTHSA - FINAL REPORT: "Trip Report to Jerry Greer RV Dealership"

[jdsr]

many thanks to driver and/or anyone else responsible for this. reguardless who is or isnt at fault, I hope we can solve this problem, if in fact it is a problem.

[Full-Timers]

So is this a "Recall"� that I should take my motorhome in and have done or just an investigation. The summary sound as though it is just in the investigation mode right now. I had the brake caliper recall done a few years back and at that time they just lubed my bell crank but did now add the zerk.

[oemtech]

NHTSA Action Number : EA07016 NHTSA Recall Campaign Number : <span class="ev_code_red">N/A</span>

It's is not a campaign or recall yet....

[oemtech]

How many of you have actually read the "Trip Report"?

I for one find 2 pages of real data, 1 page cover sheet and 13 pages of advertisement not much of a trip report. If I had turned in something like to my boss I probably would have got to do it over. Also, who/whom ever copied it did really poor job!!!

I can't image that a NEW, less than 900 miles, 37' motorhome being tested in 34 degree weather and driven less than 15 miles is any kind of test. Even a baseline test is a stretch. At least they could do is repeat this test in the middle of July in Texas on I-10 when it is 100 degrees and the drive though some Houston traffic.

I am not impressed.

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by oemtech:
I am not impressed. </div></BLOCKQUOTE> I guess that we will draw from your conclusion is that the NTHSA is not to be believed! It also raises the question as to whether or not they are the experts which there is no question in my mind that they are. I can only draw from what I read that each publication stands on its own merritt.

I think you are dropping the ball on the later part of the engineering test. I believe that all the data that they could muster regarding that particular product was compiled as a point of reference. They wanted to present a picture of the unit and any and all reference materials pertinent to the exemplar vehicle. I don't believe that it was ever intended to present as advertising.

Although we see a lot of concern from our members regarding the EA, NTHSA engineers themselves wrote the NVS-210 therefore which publication is more appropriate? I think we need to reinforce the fact that what is going on regarding the EA and the NVS remains an investigation and the results are inconclusive.

If you want we can take my motorhome (or yours for that matter) in the middle of July in Texas on I-10 when it is 100 degrees and the drive though some Houston traffic. I believe that the results that would be obtained from my motorhome would remain consistent with my current nominal operating profile.

[M&EM]

Seems like a perfectly reasonable trip report. It described what they set out to do and did.

Supplemental pages are perfectly reasonable to be included to describe to upper management the scope of the vehicle.

Establishing a benchmark for comparison is also necessary regardless of whether its new or used, hot or cold.

Marty

[jdsr]

oem tech, I totaly agree. If and I say If this is the only test this is a BIG joke. I can only hope this is the first of many tests to come. but before I get out the phone and start making calls and get the pen and paper and start writing letters I will wait and see what are hopefully more tests to come.

[oemtech]

You can draw any conclusion you want... But, I feel they need to run that same set of tests on a random selection of motorhomes. I just felt is was a bit weak as far as a report goes. I am not sure what the interior shots of the coach has to do with the brakes.

JDSR - It is not a joke... There is a potentially very serious issue here... my personal safety and yours.

You could use your Crystal Air as an example of poor testing and the removal of dual fans and etc etc etc need I say more.

[jdsr]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by oemtech:
You can draw any conclusion you want... But, I feel they need to run that same set of tests on a random selection of motorhomes. I just felt is was a bit weak as far as a report goes. I am not sure what the interior shots of the coach has to do with the brakes.

JDSR - It is not a joke... There is a potentially very serious issue here... my personal safety and yours.

You could use your Crystal Air as an example of poor testing and the removal of dual fans and etc etc etc need I say more. </div></BLOCKQUOTE> oem tech, dont misunderstand, I know this brake issue is not a joke. beleive me I know. with 3 brake failures and one happening just 5 weeks after a wh shop repaired mine, not a joke. what I meant was if this is all the testing they are going to do then the investigation imo would be a joke.

[jdsr]

[QUOTE]Originally posted by DriVer:
[QUOTE]Originally posted by jdsr:
.... I totally agree....this is a BIG joke. DRIVER, If you are going to write what I wrote, dont take it out of context. This is what I wrote. oem tech, I totaly agree. If and I say If this is the only test this is a BIG joke. DRIVER,Did you notice the period{.} after the word agree and then I started a new sentence. Its amazing how someone can turn things around by leaving out or adding words. As far as having a personal vendetta, If you call letting people know about the nhtsa investigation on brake failures and if theirs is related to report it, than yes. Thats not what I would call it but you can call it anything you want. I know where you stand. DRIVER STATED; Personally, I will be patient and I will wait for all the data to be collected before arriving at any type of conclusion. If I were you I would reserve comment and my remarks until all the facts are known. DRIVER, Because of the restrictions of this laptop I cant read what I wrote outloud
to you so I will copy and paste it. JDSR STATED:but before I get out the phone and start making calls and get the pen and paper and start writing letters I will wait and see what are hopefully more tests to come............
I think the key word here is WAIT. I said I would wait and see. I hope this clears up anything you did not understand. Now you have a great day and If I can be of any more help please let me know.

[Tom N]

Seeing reports of some owners having NO brake failures and reports of a few having 2 or even 3 failures leads me to believe hardware (with proper maintenance) may not be the problem.

Possible cause, lack of proper maintenance and/or improper application of the brakes. Also, failure to use the transmission to assist braking of a heavy vehicle.

-Tom

[DriVer]

jdsr, My position is clear in that I share what I know as fact and remedy when appropriate. I believe your position is very clear and at times over stated. It is unfortunate that these issues have presented themselves to you however your issues are basically your own. We have not established a direct coloration between what happened to you or what happened to anyone else.