Investigation EA07016: 2000–2005 Workhorse W20

Status

CLOSED

Opened

Nov 16, 2007

Closed

Aug 19, 2009

Model years

2000–2005

Subject

Overheating disc brake caliper

Component: Service brakes, hydraulic

Summary

The ea was opened to gain a technical understanding of the causes for one or more disc brake calipers on a subject vehicle to suffer severe overheating. The overheating caused brake drag, melting abs sensors, smoking, brake lining fires, and in some cases boiling brake fluid resulting in diminished stopping capability.based on testing, warranty and complaint data analysis, field trips and interviews with owners, mechanics and service managers, odi believes the likely cause of the alleged defect is water swell of the phenolic caliper piston and subsequent failure of the piston to fully return after the pedal is released.a technical report is attached with full details.

An NHTSA investigation looks into whether a safety defect exists. Opening one is not a finding. Outcomes can include a recall, closure without action, or further inquiry.

Model years covered

• 2004 Workhorse W207 complaints
• 2003 Workhorse W2011 complaints
• 2002 Workhorse W206 complaints