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willie220's avatar
willie220
Explorer
Jun 08, 2013

Brake Woes/ recall fix on Work Horse 22P

I took my 2004 Bounder in for its annual chassis maintenance: oil change, lube, generator service and chassis check. Then I got a call that made me just sick. I was informed that both of my front brake calipers were seized up. The right one so tight it had completely worn the pad down and had scored the rotor beyond repair and the heat buildup had even cracked the rotor. The left side still had some pad left but, the heat buildup had cracked the rotor on that side also. All of this had happened in just a few thousand miles. I hadn't noticed any pulling since the calipers were seizing on both sides. I hadn't any indicators that there was a problem with the brakes at all when we had it out. The sensors haven't been checked yet to see if they were or are working. We had the recall "fix" done in November 2010. Took the coach out for a cross-country trip for 5 months in 2011 putting about 10,000 miles on it. Everything checked out ok when it was serviced in fall 2011. Took it out for only 8 weeks last year, 2012 putting a little over 2,000 miles on it. I do take it out for a drive every month to keep all of the fluids and everything moving. Now I am looking at a major expense in getting fixed what I feel the recall fix failed to do. Anyone else out there have a problem since their Work Horse brake recall fix????:(
Class A

9 Replies

  • khahuna's avatar
    khahuna
    Explorer
    Jun 21, 2013
    Have you lubbed the caliper slides? Corrosion (rust) builds up on these and the calipers don't release causing heat and seizing of brakes.
  • bsinmich's avatar
    bsinmich
    Explorer
    Jun 21, 2013
    Lobstah wrote:
    bsinmich wrote:
    Have you flushed brake fluid like they told you to do on the recall? I had my recall done in 9-09 and have not had any problems since. The moisture buildup in the fluid will cause corrosion in the metal parts of the brakes. I have flushed my fluid 2 times since the recall. 3 weeks ago they said the fluid looked very clear yet but did use 1.5 L to flush the entire system. The previous one I did with my son on the driveway.


    I'm not clear on exactly what metal parts suffer corrosion due to water in the brake fluid? It will certainly reduce braking, but what parts does it come in contact with that would corrode?

    Jim

    The last time I looked the calipers, ABS, and master cylinder were all metal and subject to corrosion. The piston is phenolic but slides in a metal bore. Check out some brakes sometime.
  • willie220's avatar
    willie220
    Explorer
    Jun 20, 2013
    Got my beloved Bounder back today after a considerable ding to the old pocketbook. Everything is working tip top now and I have safe brakes at last. Replaced the start battery and the house batteries, too. Now to get the Hubby and Son to get the outside washed and waxed. Then put it on the market. I am hating to have to give her up but there comes that time to do so. :)
  • willie220's avatar
    willie220
    Explorer
    Jun 09, 2013
    As a disabled female driver I depend on my garage to keep things in tip top shape. We also had the coach serviced at our local Camping World for furnace, AC, propane, etc. I am dismayed at the situation because 1. it happened and 2. the sensor light never came on. It scares me to think I could have had a total brake failure. Once I get my Bounder back repaired it is going up for sale. I am done. I enjoyed it for the past 4+ years , but I think I'll just stick to my mini-van and HoJos from here on out. Any one wanting a well maintained gently driven motor let me hear from you. :)
  • ArchHoagland's avatar
    ArchHoagland
    Explorer
    Jun 09, 2013
    I had ours done a few years ago and have not had a problem. I never did have a problem with them and I suspect it's because mine gets used a lot.

    I see that you do the same so I'm a bit surprised. Have you talked to the shop that did the original recall work?

    Sitting for months at a time is what creates problems with the brakes but that doesn't appear to be the problem here.

    I use an IR gun every time I stop on all my tires both coach and toad. A dragging brake would show up immediately.
  • Lobstah's avatar
    Lobstah
    Explorer
    Jun 09, 2013
    bsinmich wrote:
    Have you flushed brake fluid like they told you to do on the recall? I had my recall done in 9-09 and have not had any problems since. The moisture buildup in the fluid will cause corrosion in the metal parts of the brakes. I have flushed my fluid 2 times since the recall. 3 weeks ago they said the fluid looked very clear yet but did use 1.5 L to flush the entire system. The previous one I did with my son on the driveway.


    I'm not clear on exactly what metal parts suffer corrosion due to water in the brake fluid? It will certainly reduce braking, but what parts does it come in contact with that would corrode?

    Jim
  • J-Rooster's avatar
    J-Rooster
    Explorer
    Jun 08, 2013
    Willie sorry to hear about what happened. You need to have your brakes checked out by a brake expert to find out exactly what caused this problem! This info will inform you what your next step will be (could it be a Workhorse caliper problem again or not?) My first tip off prior to the Workhorse recall was my brake sensor dash light came on. As you know when your brakes start to heat up that sensor dash light is suppose to come on! Keep us posted on what is going on!
  • bsinmich's avatar
    bsinmich
    Explorer
    Jun 08, 2013
    Have you flushed brake fluid like they told you to do on the recall? I had my recall done in 9-09 and have not had any problems since. The moisture buildup in the fluid will cause corrosion in the metal parts of the brakes. I have flushed my fluid 2 times since the recall. 3 weeks ago they said the fluid looked very clear yet but did use 1.5 L to flush the entire system. The previous one I did with my son on the driveway.
  • LindsayRichards's avatar
    LindsayRichards
    Explorer
    Jun 08, 2013
    Work Horse was initially replacing the calipers with new old design calibers until the new ones were available (if f failure occurred like in my case). I had several repairs doing this time. I had not heard of any of the new design units failing. You can get all of the info along with photos of the old and design serial numbers at IR2.com workhorse chassis forum. I sure hope these are not the new design as their are 50,000 coaches out there with them including them. Please post the results of your troubles. YIKES

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