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11-06-2021, 12:16 PM
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#1
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Junior Member
Join Date: Mar 2021
Posts: 17
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W22 Brake Caliper Recall
I have a 2007 Itasca Suncruiser 35L on the W22 Chassis. Right now I have a somebody out with it on a rental through RV Share and they're stuck in Arizona with "brake failure". The mobile mechanic came out and said the seal on the right rear caliper is bad which is preventing the pad from getting pulled off the rotor and the inside pad is down to nothing which destroyed the rotor too. He also said the left side is starting to do it and will need the same thing done over there. I found that there was a recall on the W22 brake calipers that seems to fit these symptoms perfectly.
So now it's on me to pay $3200 for new calipers, rotors, pads, and bearings. Can anybody tell me if the recall was done on mine? VIN is 5B4MP67G873422227. Also, if it hasn't been done, is Workhorse still performing the recall free of charge, or am I SOL?
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11-06-2021, 05:45 PM
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#2
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Senior Member
Join Date: Oct 2002
Location: Madison, MS
Posts: 10,521
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Quote:
Originally Posted by mmnelson553
I have a 2007 Itasca Suncruiser 35L on the W22 Chassis. Right now I have a somebody out with it on a rental through RV Share and they're stuck in Arizona with "brake failure". The mobile mechanic came out and said the seal on the right rear caliper is bad which is preventing the pad from getting pulled off the rotor and the inside pad is down to nothing which destroyed the rotor too. He also said the left side is starting to do it and will need the same thing done over there. I found that there was a recall on the W22 brake calipers that seems to fit these symptoms perfectly.
So now it's on me to pay $3200 for new calipers, rotors, pads, and bearings. Can anybody tell me if the recall was done on mine? VIN is 5B4MP67G873422227. Also, if it hasn't been done, is Workhorse still performing the recall free of charge, or am I SOL?
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I have replied to your email.
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11-07-2021, 08:12 AM
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#3
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Senior Member
Join Date: Jun 2011
Posts: 212
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The garage that does the recall puts a yellow sticker in the engine compartment under the hood
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11-07-2021, 09:15 PM
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#4
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Senior Member
Join Date: Mar 2019
Location: Arizona
Posts: 2,205
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My recall was done free of charge two years ago. Can't tell you if that's still the case.
__________________
2004 National Dolphin LX 6320, W-22, 8.1, Allison 1000, Front/rear "Trac" Bars & Anti-sway Bars, Sumo Springs, Roadmaster Reflex Steering Stabilizer, 2005 PT Cruiser Toad
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11-08-2021, 08:08 AM
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#5
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Senior Member
Join Date: Jun 2011
Posts: 212
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WOW My free recall cost me 2480$ at R@R RV in Washingggton State.
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11-09-2021, 09:36 AM
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#6
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Senior Member
Join Date: Oct 2002
Location: Madison, MS
Posts: 10,521
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Quote:
Originally Posted by fayjim2
WOW My free recall cost me 2480$ at R@R RV in Washingggton State.
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You should have had to agree to let them replace other components not covered by the recall, as described below:
The recall, 51101-C, provides 4 calipers and a QT of DOT3 brake fluid plus the labor to jack the coach, remove all 4 wheels, remove the OE calipers and install the improved version calipers with the existing pads reinstalled. Nothing more.
More than 10 years ago, when WCC existed, as a goodwill gesture, they would also replace other parts such as pads, ABS sensors, rotors, etc. but only IF the shop would provide pictures proving these components were "collaterally damaged" by the defective calipers. Navistar was never legally obligated to include those items, and is not doing any "goodwill" now. IMO, those owners who have chassis with open recalls are lucky that Navistar is still completing this "brake recall", at all.
Now that Navistar has been absorbed into the VW conglomerate, I don't know how much longer Navistar will continue completing 51101-C, but I'm guessing the recall won't last "forever".
For future readers of this thread owning any W-22 series chassis (only), IF your chassis recall has not already be done, I suggest you act promptly.
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11-10-2021, 07:30 AM
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#7
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Senior Member
Join Date: Jun 2011
Posts: 212
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So actually what was the problem with the original calipers?
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11-10-2021, 08:49 AM
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#8
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Senior Member
Join Date: Aug 2016
Location: Pa
Posts: 648
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Quote:
Originally Posted by fayjim2
So actually what was the problem with the original calipers?
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The phenolic piston used in these calipers would slowly absorb brake fluid over time causing them to swell and become stuck in the caliper bore. You apply the brakes and the hydraulic pressure pushes the piston out but it doesn't retract so the pads never completely release which causes the brakes to over heat. The hotter they get the tighter they drag. My coach had the recall completed in 2010 and I suffered a failure again this summer on one wheel, so decided to replace the entire brake system (calipers, pads & rotors) rather than take a chance on another roadside repair. FYI: I discovered one other caliper was on the way to having the same failure
Tom
__________________
2004 Coachman Santara 3480DS Workhorse w-22 Ultra Rv tune with Banks headers, Koni shocks
Retired OTR driver ATA 5 million mile safety award
USMC Vet 1968-1972
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11-10-2021, 10:08 AM
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#9
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Junior Member
Winnebago Owners Club
Join Date: Nov 2016
Location: Green Valley
Posts: 11
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Can you tell if my Itasca 2004 33v has had the recall done?
Vin -- 5B4MP67G243378818
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11-10-2021, 12:31 PM
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#10
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Senior Member
Join Date: Oct 2002
Location: Madison, MS
Posts: 10,521
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Quote:
Originally Posted by Wilgarrison
Can you tell if my Itasca 2004 33v has had the recall done?
Vin -- 5B4MP67G243378818
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That chassis is a 2004 model year W-20 (GVWR=20,700 pounds). It had the usual 3 recalls, including 51101-C to replace all four OE calipers. It was done 9-22-2010 @ 32,793 miles.
IF you want the build sheet and more details, send me an email so I can attach it to a reply : edgray1@gmail.com
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11-11-2021, 07:35 AM
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#11
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Junior Member
Join Date: Mar 2021
Posts: 17
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Sure seems like they didn't actually fix the problem, I've seen a lot of people on here who already had the recall performed and had a repeat issue. Ed told me that mine was done in 2010 (Thanks Ed!) and now the rear right caliper has a repeat of the issue and the mechanic said the one on the left is starting to have issues as well so he's doing both sides. He said the fronts look good though.
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11-11-2021, 09:43 AM
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#12
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Senior Member
Join Date: Jun 2011
Posts: 212
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So if the caliper pistons would stick and not retract why did I have to pay for all rotors and assorted brake parts. I would think R@R RV in Liberty Lake Wa. should have done me better.
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11-11-2021, 07:11 PM
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#13
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Senior Member
Join Date: Oct 2002
Location: Madison, MS
Posts: 10,521
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Quote:
Originally Posted by fayjim2
So if the caliper pistons would stick and not retract why did I have to pay for all rotors and assorted brake parts. I would think R@R RV in Liberty Lake Wa. should have done me better.
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As I posted in #6 above:
The recall, 51101-C, provides 4 calipers and a QT of DOT3 brake fluid plus the labor to jack the coach, remove all 4 wheels, remove the OE calipers and install the improved version calipers with the existing pads reinstalled. Nothing more.
Did you really expect the dealer to just give you all the other parts that were apparently needed ? Hopefully they at least showed you the damaged parts, convinced you they were actually needed, and got your permission to replace them.
MOCOTOM (above) has provided a good summary of the problem with the OE version of the Bosch calipers that failed (swollen phenolic pistons). However, it was MOISTURE that becomes absorbed into the DOT 3 fluid that actually caused the pistons to swell in their bores and prevent the pistons from fully releasing the pressure on the pads, causing the pads to drag against the rotors creating excessive heat and collateral damage.
Since the root cause was determined to be the hygroscopic nature of brake fluid, WCC changed their service interval to replace of this vital fluid every 2 years, regardless of mileage.
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11-11-2021, 07:27 PM
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#14
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Senior Member
Join Date: Oct 2002
Location: Madison, MS
Posts: 10,521
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Quote:
Originally Posted by mmnelson553
Sure seems like they didn't actually fix the problem, I've seen a lot of people on here who already had the recall performed and had a repeat issue. Ed told me that mine was done in 2010 (Thanks Ed!) and now the rear right caliper has a repeat of the issue and the mechanic said the one on the left is starting to have issues as well so he's doing both sides. He said the fronts look good though.
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Not sure I would agree with the term "a lot" because the total number of chassis recalled to replace the OE calipers exceeded 50,000, = to over 200,000 calipers.
IF the failure rate of the "improved " calipers was "a lot", I would think someone would have convinced NHTSA to mandate another recall. AFAIK, that hasn't happened. Bosch brake caliper recall 51101-C was issued in September 2010, and unfortunately, there are STILL chassis out there with that recall open. I average finding about one per week, (11 years later) where a new owner is hearing about it and I'm able to help them find a way to get it done.
As I have posted many many times, moisture that becomes absorbed in the hygroscopic brake fluid is believed to be the root cause of the swollen pistons, and the best preventative action is to replace the fluid every 2 years-even after installing the improved version calipers. IMO, compared to the cost and potential damage that can occur when a caliper sticks, fresh brake fluid is cheap PM.
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