Rotor Cracks

[nyrngrz]

I just finished a cross country trip, now have 20K miles on my Workhorse Chassis and brought the coach in for service. The ABS light was staying on periodically. I am being told that all 4 rotors are blue and cracked, basically destroyed. The pads on all brakes are fine and not worn out. The estimate to replace all rotors and since the pads could stick with the new rotors, replace the brake pads as well, we are talking $2800.00. As you can see from the brake pads not being worn, I do not ride the brakes and only have 20K miles on the coach. Do I have an issue with Workhorse? Has anyone else experienced this problem? I
appreciate any assistance.

[nyrngrz]

I just finished a cross country trip, now have 20K miles on my Workhorse Chassis and brought the coach in for service. The ABS light was staying on periodically. I am being told that all 4 rotors are blue and cracked, basically destroyed. The pads on all brakes are fine and not worn out. The estimate to replace all rotors and since the pads could stick with the new rotors, replace the brake pads as well, we are talking $2800.00. As you can see from the brake pads not being worn, I do not ride the brakes and only have 20K miles on the coach. Do I have an issue with Workhorse? Has anyone else experienced this problem? I
appreciate any assistance.

["007"]

nyrngrz welcome to the Workhorse forum and irv2.
As you can see by this THREAD you may not have a problem. I have 25000 and the rotors look the same as others have stated.

[DriVer]

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by nyrngrz:
I just finished a cross country trip, now have 20K miles on my Workhorse Chassis and brought the coach in for service. </div></BLOCKQUOTE>May we have your year and model please ... I might help us answer your question a little easier.

[nyrngrz]

Sorry. I was under the impression my profile would show that information. I have a 2003 Holiday Rambler Vacationer(Gas), W22 Workhorse chassis.

[paz]

nyrngrz, welcome to iRV2.

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by nyrngrz:
Sorry. I was under the impression my profile would show that information. I have a 2003 Holiday Rambler Vacationer(Gas), W22 Workhorse chassis. </div></BLOCKQUOTE>
If you want your coach information to show up on your posts, you have to go back and re-edit your profile. Make sure you are logged in and click GO at the top of this page. Then click PERSONAL ZONE, then click PROFILE. At the top right of your profile page, click VIEW/EDIT COMPLETE PROFILE. Scroll about halfway down the page and fill out the information you want in the box labeled SIGNATURE. After editing your profile, scroll down and click SUBMIT.

[JCM]

W22 - 2003 models are known to have that problem. All mine were cracked and replaced along with cooked ABS sensors on the rear wheels.
When the front rotors were replaced in 2005 I was blamed for ridding the brakes. After I protested a lot, Workhorse paid for the parts and I paid for the labour (about $500.00). When I got home (3500 miles away) I crawled under the coach and felt the rear rotors only to find that they were also cracked - not checked by the Workhorse center in Apachie Junction even though they replaced the rear ABS sensors saying that they were overheated. I called Workhorse and the rep said it was a known problem and he arranged to have my rear rotors replaced by a non Workhorse service center as there are NONE available in central and northern BC. He was extreemly cooperative and everything went ok. According to him W22 - 2003 chasis were released with improperly lubed caliper pins allowing dragging of the brakes. This was before the zerk fitting was required.
I would approach Workhorse and send a report to the US investigating agence - posted elsewhere on the form.
I hope this helps.

[M&EM]

JCM,
Was the workhorse service center in Apache Junction "Apache Sands"?
I had my cracked rotors and worn outer pads(32kmiles) replaced there. Although WH picked up the tab, I was not happy with Sands diagnostic evaluations and honesty in services performed and quality of care given to my coach. I would not return there with other choices in the Phnx area.

Although caliper replacement was not deemed needed then, I worry often about the problem recurring during these last additional 13k miles.
I use brakes tenderly and sparingly and still see surface cracks showing up on the replaced rotors. Brakes have not gotten hot enough to smell or leave rotors discolored. At this point observations seemed to be within whats reported as normal

[FLYTYER]

This is scary stuff ! With this thread and the earlier threads on the same topic, I began to wonder about the seriousness of this brake situation.

By reading back through the posts, I came to the conclusion that we do not pay enough attention to the recommended WH maintenance schedule. When this earlier became a hot topic, I wondered then how many who reported problems actually had been following the WH schedule. There may be no answer to this, but I'll bet we have a handful of owners who have not.

I recently had my brakes serviced by an independent garage who does a lot of motor home work in our area. The owner who also owns a motorhome, told me he suggests brake maintenance every 12,000 miles or once a year. He claims that in the years of doing this none of his motor home customers have had a problem.

To me the brakes are the most important part of a motor home, so a $300 service cost each year is worth it.

[JCM]

Yes it was Apache Sands. They replaced my front cracked rotors - gave me a hard time and never checked the rears even though they replaced the ABS sensors which were melted (according to them). I wouldn't go back. I think I would rather go to a Wal Mart service center - more professional.
As to Flytyer - I agree preventative service is a good idea but these 2003 models came out of the factory with non lubed calipers and there wasn't any warning to the owners till after the fact. In fact I never received a recall - cheaper for me and Workhorse if they had.
I also had a defective dash, squeeky front springs, a defective heater valve, front shocks replaced re bouncing, broken manifold bolts (replaced with Banks headers to prevent future problems at my expense), a broken radiator bracket, a sheared oil pump shaft (over tempered according to Workhorse - no recall. I also have never received a recall notice for the zerk fitting but after reading about it did it myself.
All these problems were in spite of preventative mantance - they were all, I feel, manufacturing defects or sloppiness. Luckly most were covered by Workhorse and I only had to drive 350 miles or more to a service center if I couldn't do it myself and none caused a injury except for an increase of blood pressure.
My question is why do they produce such junk and expect us to continue being loyal. I had a Ford 450 - 30 foot Bigfoot and I had to replace the torsion bars (IPD) and shocks just to keep it on the road. I agree it was not Ford but Bigfoot that overloaded and "streatched" the Econoline van chassis - it was 1800 LBS over gross when I went across the scales one day. I got rid of it immediately and bought a better product in the Workhorse chassis - or did I?
My Toyota cars run for 6-15 years with little repairs. Why can't motorhome manufactures either produce a chassis that is worth the higher price or get one from a foreign manufacturer who has learned in the last 100 years how to make something that works "out of the box".
I don't mind doing preventative maintance but I shouldn't have to rebuild the unit after I buy it. It is like a software manufacturer (Roxio) that releases beta quality product due to a schedule and have the customers thrash their computers trying to get it to work and then later releasing a "fix" to bring the product up to a reasonable level of usefulness to the consumer. Yes I was a beta tester for them for years but quit when things changed.
I needed to vent my spleen - thanks.
I still like the Workhorse design but wished it worked as it is sold.

[Corkey]

It's a tough sell to compare MH's to cars. Toyota builds the whole car, .... now if Workhorse built the entire motorhome things would get VERY interesting as the "grey" areas would disappear, and comparisons would take on a whole new life.

Just my thoughts, ...

[Bucky1]

These rotor cracks are interesting. My 2000, 3/4 ton chevy truck had a similar problem. Disks on all 4. Felt a vibration that wouldn't go away. Shop checked the rotors up front....The one honestly looked like it wouldn't have stayed together much longer. The other had cracks, but not as bad. The rears didn't look a lot better. Updated the rotors to some slotted and drilled ones while I was at it. Much better braking, and no cracks so far. Don't know if it is the same thing, but sounds similar.

[rvjer]

I had the same problem on my 03 W-22 at about the same mileage. Mine was found while getting some other work done at Brazil's in Wa. They were great in calling Workhorse and finally got them to agree to replace them under warranty. I did have to make a $100.00 deductable payment to them but that was the total out of pocket cost.

[nyrngrz]

Did your VIN fall under the recall?