NHTSA Action Number : EA07016; Regarding, Service Brakes Hydraulic

[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:
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.
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