W/H Protocol

[obbm]

This from the Bounder forum:
Posted by: "Jerry Newberry" peskyfeller@earthlink.net peskyfeller

Mon Sep 13, 2010 2:35 pm (PDT)



Hey Gang, This is for the folks driving the w20 and w22 Workhorse
"WC"chassis. As you should know the recall has begun. I had mine performed a
week ago. I want you all to be aware of a flaw in the protocol they are
sending repair centers.

Workhorse is paying dealers a set amount for performing the recall. This
comes to 3 1/2 hours labor but the max hourly charge is set by Workhorse. In
some places this is well below the normal hourly rate charged.

The service centers (SC) are sent four calipers and two quarts of DOT III
Synthetic brake fluid for each coach. The fluid is rated to have a boiling
point of 450 degrees. Not bad. The problem is the system needs three quarts
of fluid for a complete flush.

SCs are directed to gravity bleed the brakes. This means opening the bleed
valves on each caliper and allowing the fluid to drip/run out of each
caliper. This takes a lot of time and there is a glitch in the protocol. Two
quarts of fluid will not replace three no matter what math you use. As a
result you are left with about 1 quart of old fluid and possibly air in the
brake system. The old fluid will contain some water and can reduce the
boiling point of the fluid in the calipers. After all the new fluid is put
in above the old fluid. In addition gravity bleeding, if not done correctly
will let air into the caliper. I prefer the pressure bleeding or good old
fashioned foot on the pedal and guy underneath bleeding method.

http://www.aa1car.com/library/2003/bf90347.htm

I was not aware of the protocol WH had placed on the SCs when I took my rig
in. The place that did my recall was a first class place and their mechanics
were very competent. The first thing they did after removing the wheels was
to come in and report to the owner that my rig had "collateral damage". I
asked what that meant and was told there was damage to the rotors and
sensors. They had to take pictures of the rotors at each wheel and fax the
pictures to WH for authorization for the repairs and for a determination of
what caused the damage. I took my own pictures for my records. There was
evidence of excessive heat on three of the rotors. That was no surprise
since at one time or another all three calipers had stuck. Two of the ABS
sensors were melted. Here are the first instructions WH sent to dealers for
the interim recall:
http://www.irv2.com/forums/f22/safety-recall-50901-c-interim-repair-procedur
e-57771.html

While they were waiting for WH to answer about who would pay for the repairs
I was surprised to see the mechanic had installed the new calipers. I asked
why and he said to save time because the calipers had to be gravity bled.
Sure enough I looked down and saw bubbles coming from the caliper bleed
valves. It took about an hour for WH to authorize turning three rotors "I
had replaced all 4 less than a year ago". They took the calipers back off
and removed the rotors and turned them. That means resurfacing the rotors on
a brake lathe.

After the recall was done the mechanic test drove the Bounder about a mile
and he was pleased with the brakes. This was Friday evening. On Saturday I
headed home and the first time I hit the brakes I noticed the brake pedal
was a bit spongy and it took more pressure to stop. I figured it was because
the antilock braking system (ABS) was working for the first time since I
bought the rig 4 years ago. I decided I just needed to adjust to the new
feel. I was just happy the brake calipers were releasing. In the back of my
mind I was wondering if the brakes had been bled properly because what I was
experiencing is classic for air in the brake lines. I drove 130 miles home
in and out of stop and go traffic.

I live on a steep hill and drove about 1/3 mile down the hill before pulling
into my driveway. I stepped out of the Bounder and smelled a familiar
smell...hot brakes. Two of my wheels were hot. Not as hot as when calipers
stuck but hotter than they should have been. I jacked up the Bounder and
climbed under for a look. I saw that there had been some pad transfer to the
rotors but that is not unusual during the "bedding in" of new brakes.
http://www.zeckhausen.com/bedding_in_brakes.htm

I sent pictures of the rotors and asked questions to some folks I trust and
asked their opinion. My thoughts were the brakes were not properly bled
therefore all 4 rotors were not working properly. This would cause the other
two rotors to do more of the work therefore causing them to heat up more. I
also went to the Workhorse forum on iRV2 This is where I learned that WH
only sent two quarts of fluid for the 4 caliper recall. Had I known that
before I would have gladly paid for the extra quart and insisted on power
bleeding the brakes.

My point here is to tell everyone waiting to have the recall done to insist
on complete brake flushing and pay for the extra quart. I will bleed my
brakes before I go out again. I have posted pictures in the Workhorse album:
http://groups.yahoo.com/group/bounder/photos/album/282480572/pic/list#

Jerry Newberry

USAF Retired

2003 Bounder 36S W22

2006 Saturn Vue


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Messages in this topic (2)
8b. Re: Workhorse Recall

Posted by: "jjohnsonjo1" jjohnsonjo@aol.com jjohnsonjo1

Mon Sep 13, 2010 5:11 pm (PDT)



Thanks for the update Jerry, mine goes in on Friday. I wish they would just give me the new calipers. Don't like wrestling with hundred pound tires and 30 pound calipers at my age, but I've done it before. Then I know its done right, even if my back hurts a little.

J.O.

[DriVer]

Quote:

Originally Posted by obbm Thanks for the update Jerry, mine goes in on Friday. I wish they would just give me the new calipers. Don't like wrestling with hundred pound tires and 30 pound calipers at my age, but I've done it before. Then I know its done right, even if my back hurts a little.

Who is doing the work?