Stuck - Brakes Will Not Release (UFO)

[ChrisFSB]

Hi Folks,

2008 Winnebago Destination UFO Chassis:

We're due to head on a Spring Break trip - and on engine start I get:

• ATC
• ABS
• AutoPark
• Hydraulic Brake Warning
• Brake Failure
• Red Stop light

The Park Brake will not release.

Previously we've had warning lights illuminate - but each time they clear up after an engine restart. The coach has been at the Workhorse dealer four times for this issue. Each time - they try hard - but apparently haven't found the root cause.

I called Workhorse 24x7 assistance this evening - on my third call I got someone helpful. Unfortunately they have no ability to assist until Monday, and then they want to tow the coach 50 miles to the dealer.

So - turning to my friends on the forums:

• Any suggestions on how to get the brakes to unlock (typically once I roll a couple of feet all errors clear up)
• Any other suggestions?

Thanks! Chris.

[UFO Pilot]

I have had the same problem a couple of times and it has always cleared by restarting the motor. Have you tried using the chassis battery disconnect switch? I don't know if it will work but you might try it.

[ChrisFSB]

Hi,

Thanks for the reply:

Quote:

I have had the same problem a couple of times and it has always cleared by restarting the motor. Have you tried using the chassis battery disconnect switch? I don't know if it will work but you might try it.

Yup - I've tried the engine restart; and also the chassis battery disconnect. No luck...

Chris.

[Midniteoyl]

Crap... Seen this before on here but cant find it ATM... try a quick search for 'auto park' or similar. Seems I remember it being an easy fix..

[gbs2320]

Not sure if this is your problem but I had failure lights come on when I pulled in to the Workhorse dealer (Price Chevy Truck in Charlottesville VA) to meet the Workhorse reps who came to town to help resolve issues on my odometer and front chassis control module and to help a number of others (one who was in hospital they even drove a couple of hours away to pick up his rig!). The reps immediately knew the problem since a number of failures had occured already and the truck center also knew the problem since these brakes are on many school buses they service. The hydraulic control unit made by Meritor Wabco has a design problem in that the piston clearances are problematic. Apparantly Meritor will replace it with a rebuilt improved unit often even when out of warranty. Workhorse had one overnite shipped from an outside source (the truck center first said they were out of stock at workhorse and not available for a couple of weeks). My brakes did not lock up but if the system is real bad I suspect that the brake computer attached to the hcu may not let you move the rig. Note also the hcu controls antilock, power brake and parking brake hydraulic functions. Workhorse was outstanding in quickly having it fixed and Truck center was also great. I reported it to NTSB but we will not get a recall unless others do the same. Note when reporting it you will not see UFO chassis listed but rather r26 I believe. Good Luck. Greg

[ChrisFSB]

Thanks for all the replies. I'm looking forward to Monday morning when I can get Workhorse on the phone so we can start figuring out the solution!

Chris.

[ChrisFSB]

Hi,

I sent a note into Workhorse and got an immediate reply from their SoCal Service Manager, and also their US Service Director.

Long story short:
- They were unaware the coach I had purchased had sat on the dealer's lot for ~3 years. When I told them this, the SoCal Service Manager immediately said "oh, I know what the problem is. We need to swap out the hydraulic brake module under the coach." Apparently, some part goes bad if the coach sits for very long periods of time.

- They will also fix the front end clunking

- They will also fix the "Backup Light Failure" message when the toad is hooked up.

To SoCal Service Manager will come to my home and figure out how to get the coach out from our tight driveway (we can't tow it out).

All in all - we have a plan - and a plan that holds water...

I'll report back in a couple of weeks when the work has been done.

Thanks all, Chris.

[JohnRR]

I hope all goes well for you.

[-Gramps-]

Chris,

How did it go? Is your coach back on the road?

[DriVer]

Quote:

Originally Posted by ChrisFSB All in all - we have a plan - and a plan that holds water... I'll report back in a couple of weeks when the work has been done.

Chris, It's been a month, how's it going?

[Arch Hoagland]

Chris is busy with the crane company lifting the motorhome over his house.

[George Z]

Quote:

Originally Posted by Arch Hoagland Chris is busy with the crane company lifting the motorhome over his house.

No , I think they were moving the house to get the wrecker in place. LOL

[ChrisFSB]

Hi Folks,

I was waiting until next week to give an update - when I hope to have the coach back...

I want to start by acknowledging Workhorse, and in particular their SoCal Rep Jesse for taking good care of us - and going the extra distance to get things right. Thanks Jesse!


Here's the update:
Workhorse's SoCal rep Jesse came to our home as promised. He hooked his laptop to the coach and our plan suddenly took a turn for the worse. The UFO's braking system has two independent boost circuits. The front circuit had completely failed - guess that explained the inability to release the park brake!

We called for a tow; the first truck was too small... so it was swapped for a larger one.

Jesse released the park brake - he's brave as you need to crawl under the coach near the rear wheels. Did I mention the coach was on a slope?

With the brakes released I was able to drive the coach out of the driveway, down the lane, and onto the street.







Drove up onto some blocks, and the tow truck hooked up. Drive shaft removed; tow lights installed and off the coach went 50 miles to the dealer.





Here's what they did:

WORKED WITH JESSE FROM WORKHORSE TO REPLACE BRAKE BOOSTER
ASSEMBLY. REMOVED BRAKE BOOSTER AND INSTALLED NEW BRAKE
BOOSTER. REMOVE BRAKE BRACKETS AND CONTROL MODULE FROM THE OLD
BOOSTER AND PLACED THEM ON THE NEW BOOSTER. CLEAN AREA WHERE
FLUID LEAKED AROUND CHASSIS. FILL BRAKE FLUID RESERVOIR.
LIFT REAR AXLE TO REMOVE REAR DUEL TIRES TO BLEED BRAKES. BLEED
HYDRAULIC BRAKES, PARK SYSTEM AND ACCUMULATORS. REINSTALL TIRES
BACK ON

The coach is now having new tires, and some other issues fixed; I'm really hoping we're done with repairs - in our first 11 months of ownership many things have been fixed - thank goodness for the warranty!

I'll report back once I've had a chance to drive with the fixed brakes.

Cheers, Chris.

[gbs2320]

Your Hydraulic Compact Unit (HCU) which is the major part of the system went bad. Mine went bad also and was replaced as noted in my earlier post. Greg