2002 Workhorse W22 Problems

What owners report

Owner complaints for the 2002 Workhorse W22 chassis are dominated by hydraulic brake problems, with the great majority of the sample describing calipers that stick or drag, burnt-smelling brakes, and brake pedals that go to the floor. Most are described at low mileage, often on RVs that sit between trips, and many owners tie events to stop-and-go traffic, long downgrades, or after a recall repair. A smaller group covers engine stalling and a few scattered electrical, lighting and suspension items.

1. 1
   Brakes

   Brake calipers sticking or dragging, overheated brakes

   • 41 complaints (61%)
   • median 30,000 mi at 6.8 yrs old (29 state mileage)
   • 5 mention a crash, fire or injury
   • filed 2005–2011

   Owners describe smelling burning brakes, seeing smoke from a wheel, and finding a caliper stuck in the applied position, sometimes with melted ABS sensors or wiring and cracked or heat-stressed rotors. Complaints say the vehicle can pull to one side, vibrate under braking, or need cooling at the roadside before it can continue. Several owners report calipers were replaced, in some cases more than once, and that the problem returned after the recall repair. Mostly reported between roughly 7,000 and 40,000 miles, often in stop-and-go traffic, after mountain downgrades, or on RVs used occasionally.

   Recall 09V110000Recall 04V084000

   What to check: Ask for records of caliper replacement and of which recall campaigns were completed, and have a mechanic check each wheel for drag, uneven heat and rotor cracking after a test drive. Check for a burnt smell or excessive heat at the wheels after driving.

   2 excerpts from owner complaints in NHTSA records

   “Coming home on the 405 freeway in los angles in stop and go traffic, my right front caliper apparently stuck on. About 2 miles from home the ABS light came on and I could smell the brakes. I went on home and the right front wheel was smoking. I let it cool. Since then I have replaced the right front caliper, the brake line and the ABS sensor. All of the other calipers appear to be ok.”

   NHTSA complaint #10246595, filed 2008-10, 30,000 miles

   “We were traveling on interstate 83 heading north past baltimore when we smelled a burning brake smell - we pulled over on the side of 83 and the front drivers side brake caliber had stuck and would not release - the rubber dust boot caught fire - the inside of the tire cracked and began to melt due to the heat - we extinguished it with the fire extinguisher. After letting the brake cool for a hour we were able to make it off the exit to a side road. This is the second brake caliber that has gone bad on this vehicle. …”

   NHTSA complaint #10266174, filed 2009-04, 41,000 miles
2. 2
   Brakes

   Recall parts unavailable or repair disputed

   • 33 complaints (49%)
   • median 20,000 mi at 6.8 yrs old (21 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2005–2023

   Many owners describe receiving a recall notice but being told by the dealer or manufacturer that caliper parts were not yet available, with waits lasting months or longer. Some say only the calipers were covered while rotors, pads and seals that had also failed were billed to them, and others describe repeated unsuccessful repair attempts or requests for reimbursement. Complaints also note that a recall repair did not stop the same symptom from returning. Described across a wide mileage range, including vehicles under 20,000 miles, and in complaints filed over several years after the recalls were announced.

   Recall 09V110000Recall 04V084000

   What to check: Before buying, confirm in writing which recall campaigns have been completed on the chassis and get the repair invoices for any brake work paid by the owner.

   2 excerpts from owner complaints in NHTSA records

   “Non-availability of parts, NHTSA recall # ea02035. I have tried to make an appt w/an authorized Workhorse chassis service center. The two centers nearest me have had the caliper kits on order for the longest time. I feel that Workhorse custom chassis is dragging their feet when supplying the service centers.”

   NHTSA complaint #10392929, filed 2011-03, 14,000 miles

   “November 16, 2007 ea07016 was opened. I still (2/24/2010) can't use my vehicle as Workhorse has not scheduled any repairs yet. Why are you letting them get away with this. The problem is known and is a safety issue.”

   NHTSA complaint #10313951, filed 2010-02, 30,000 miles
3. 3
   Brakes

   Brake pedal goes to the floor (loss of braking)

   • 10 complaints (15%)
   • median 32,870 mi at 6.6 yrs old (9 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2007–2023

   Complaints describe the brake pedal traveling to the floorboard with little or no stopping power, sometimes preceded by a flashing ABS light or a soft, spongy pedal. Owners report having to pump the pedal or let the vehicle coast to a stop, and repairs often included calipers, hoses, ABS sensors and boiled or contaminated brake fluid. Some owners say the condition was intermittent or could not be reproduced by the dealer. Reported from about 8,000 to 48,000 miles, sometimes on a single trip after repeated braking or while driving at highway speed.

   Recall 09V110000Recall 04V084000

   What to check: Press the pedal firmly with the engine running and confirm it holds rather than sinking; check brake fluid condition and whether the ABS light stays on. Ask whether the brake fluid and hoses have ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Coming home from camping,in traffic when ABS light comes on. There's a smell of burning brakes. Rv seems to be under a heavy load. After a few stops braking gets harder. By the time I make it home almost a complete brake failure. Brake pedal goes to the floor. Pumping the brakes maintain some stopping control. Parked rv and seeking help.”

   NHTSA complaint #10228805, filed 2008-05, 12,420 miles

   “Incident in england: soft pedal & loss of braking, on imported american motorhome (rv). There are thousands of imported rvs here. My vehicle is a 2002 'trail lite 262' by r-vision on a Workhorse chassis. It is used regularly & has 35,000 miles. A recent service noted the brake calipers were free to move, but suitable lubricant was applied as a precaution. Two weeks ago, approaching a sharp double bend at 40 to 50 MPH, the brake pedal went to the floor with no retarding action. …”

   NHTSA complaint #10286359, filed 2009-10, 35,000 miles

Buying note. The brake system is the main thing to investigate on this chassis: get documentation of which recalls were completed and have the brakes inspected for drag, heat damage and rotor cracks. A pre-purchase inspection by a shop familiar with Workhorse chassis is worthwhile, and confirm that recall parts and service are still obtainable for the vehicle.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.