Investigation PE07032: 2000–2005 Workhorse W20

Status

CLOSED

Opened

Jun 25, 2007

Closed

Nov 19, 2007

Model years

2000–2005

Subject

Overheated brake calipers

Component: Service brakes, hydraulic

Summary

On june 25, 2007, the office of defects investigation (odi) opened a preliminary evaluation to investigate alleged overheating disc brake calipers and poor brake performance in model year (my) 2000-2005 workhorse chassis recreational vehicles.currently odi is aware of 651 specific complaints on the subject vehicles (odi and workhorse complaint population).odi analysis of the warranty and complaint data furnished by workhorse on september 11, 2007, in response to odi's information request indicates a dramatic drop in brake related complaints after the may 2004 build date.at that time, workhorse incorporated into production zerk fittings and greasing of the brake master cylinder's bell crank linkage.odi is also aware of 3,782 unique warranty counts related to the alleged defect in the subject population.a review of the warranty claims reveals that of the claims filed, only 88 were submitted on vehicles produced after the may 2004 production line change (addition of zerk fittings).odi intends to obtain an understanding of why there are seemingly significant differences in the complaint data and warranty claims before and after the may 2004 design change and the safety consequences of the pre-change design. This investigation has been upgraded to an engineering analysis (ea07-016) for further investigation.

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