2003 Workhorse W22 Problems

What owners report

Owner complaints for this model year are almost entirely about the hydraulic disc brakes on these motorhome chassis, with the Bosch pin-slide caliper the recurring theme. Reports describe calipers that stick or fail to release, hubs and rotors that overheat, and a brake pedal that goes to the floor, often followed by a long wait for recall parts. Many of the filings are as much about repair and reimbursement frustration as the symptom itself, and mileages are usually low for the age of the coach.

1. 1
   Brakes

   Sticking calipers, overheated brakes and long pedal

   • 71 complaints (63%)
   • median 23,930 mi at 5.6 yrs old (52 state mileage)
   • 6 mention a crash, fire or injury
   • owner-quoted repair $2,000 (median of 11 quotes)
   • filed 2005–2011

   Owners describe a brake pedal that goes to the floor with little or no warning, sometimes after the coach starts pulling to one side, and a burning smell or visible smoke from a wheel. Several say the affected brake stayed applied and the hub got hot enough to damage seals or boil the fluid, and that the braking returned to normal only after everything cooled. Dealers and service centers are reported to have replaced calipers, pads, rotors and ABS sensors, with costs varying widely between repairs. Reported from roughly 3,000 to 54,000 miles, often on coaches driven occasionally or seasonally and after stop-and-go or long-distance highway runs.

   Recall 09V110000

   What to check: Ask for the recall repair history on the chassis and whether the calipers were rebuilt or replaced. On a test drive, let the coach sit briefly and touch each wheel hub for uneven heat, and check the brake fluid for darkening or a burnt smell.

   2 excerpts from owner complaints in NHTSA records

   “26 may 2009 - while driving my 2004 national dolphin (Workhorse w-22) motorhome from cocoa beach, fl toward my destination, home, I encountered a strong pull of the vehicle to the right. Stopping and making an inspection of the front wheels revealed the right hub was very hot and a smell of hot brakes. I carefully made my way to the next campground; there I was able to contact an rv repair service. With their mobile service they came to the campground and made an inspection. …”

   NHTSA complaint #10274799, filed 2009-06, 24,000 miles

   “Regarding the bosch brake recall, I experienced no brakes when they overheated in august, 2009. The brake pedal went to the floor when applied. Thankfully I was near my destination and contacted a repairman that informed me that once they cooled down, the brakes would work again and they did. My problem is that I recently contacted Workhorse who advised that they still do not the parts to correct my recall that I received back in the early spring of 2009. What's up with that? …”

   NHTSA complaint #10290759, filed 2009-11, 38,000 miles
2. 2
   Brakes

   Recall parts unavailable for months

   Mentioned in 9 of 60 sampled complaints

   Many complaints are about the recall process rather than a new symptom: owners say they received an initial notice and later interim notices stating the remedy parts were not yet available. Some report waiting many months, being told no timeframe was known, and in a few cases being offered temporary repairs with unclear responsibility for the cost. Other owners say their coach was excluded from the campaign and that repair costs for calipers, rotors and sensors were handled differently case by case. Mostly filed between late 2008 and early 2011, on coaches with mileage ranging from under 10,000 to about 54,000.

   Recall 09V110000

   What to check: Ask the chassis manufacturer or a dealer to confirm by VIN whether the recall remedy was completed, and keep the paperwork for any brake work done at the owner's expense.

   2 excerpts from owner complaints in NHTSA records

   “In may 2009 I received notification from Workhorse custom chassis that our motorhome was involved in safety recall 50901-c. The information available today from their customer service and website is the very same as it was in back in may ( problem identified, parts not available). I find it hard to believe that in seven months Workhorse hasn't been able to resolve this safety problem or provide those affected with more up to date information on the actions being taken. …”

   NHTSA complaint #10291298, filed 2009-11, 27,970 miles

   “-the contact owns a 2003 Workhorse W22 chassis. The contact stated that in may 2009 he received his first recall letter. A letter regarding the recall was received in december 2009 which stated the parts for the recall remedy were being manufactured. The sensors, calipers and rotor were repaired at the owner expense. The manufacturer reimbursed for the caliper repair. However, the manufacturer refused to reimburse for the sensor or rotor service repair. The failure mileage was 43,000. The current mileage was 44,000.”

   NHTSA complaint #10326314, filed 2010-04, 43,000 miles
3. 3
   Brakes

   Cracked or warped rotors and premature pad wear

   • 14 complaints (12%)
   • median 36,233 mi at 6.4 yrs old (9 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2007–2018

   Complaints describe rotors with radial cracks through the disc, severe surface cracking, vibration or shimmy under braking, and pads wearing out much sooner than owners expected. Several owners say the cracks were found during routine tire changes, recall visits or inspections rather than from a specific failure, and that uneven pad wear pointed to a dragging caliper. Repair estimates in the complaints range from a few hundred dollars to several thousand when rotors, pads and related parts are replaced together. Mostly reported between about 13,000 and 54,000 miles, in some cases discovered during service for another brake concern.

   Recall 09V110000

   What to check: Have the rotors inspected on a lift for cracks and scoring rather than relying on a road test alone, and ask for the last brake service invoice showing what was replaced and at what mileage.

   2 excerpts from owner complaints in NHTSA records

   “Abs light came on and I went to have the vehicle serviced. The service tech showed me the rotors and calipers. They were badly cracked and overheated. Cost $4700 to repair. Would not warranty them because the computer code said I was riding the brakes. False . They installed a zerk fitting on the shaft to the bell crank without documenting it.”

   NHTSA complaint #10260291, filed 2009-02, 37,230 miles

   “Noticed during a recent tire change that 3 out of 4 rotors had radial cracks completely through the disk. One on each rotor and two on the right front. No cracks were noted on the right rear. These cracks are only on the outer disk. No other cracks were found with the exception of light surface cracks on all inner and outer rotors.”

   NHTSA complaint #10274425, filed 2009-06, 33,758 miles
4. 4
   Brakes

   ABS warning light and damaged wheel sensors

   Mentioned in 5 of 60 sampled complaints

   Owners report the ABS warning light coming on and staying on, sometimes alongside a pull to one side or a spongy pedal. Service visits are described as finding wheel sensors and seals damaged or burned off by heat from the brakes, and some complaints say the sensors were cleaned or replaced and the light returned months later. A few owners say the issue was connected to the same caliper heat that affected the rest of the system. Reported from roughly 10,000 to 39,000 miles, often shortly after a brake overheating episode.

   Recall 09V110000

   What to check: Confirm the ABS light is off with the engine running and after a short drive, and ask whether wheel sensors or ABS components have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “We drove 300 miles and felt the rear calipers hanging up on 3 occasions. As soon as we got on the interstate, we felt the mtrhome had no power, as if the brakes were being applied and then smelled burning brake odor. Stopped at the first rest area in a couple of miles, let them cool for 2 hours, then they did release and as long as we were on the interstate not using brakes, we were fine. As soon as we got off the interstate to go to the rv park, within 2 miles, the brakes once again heated up but not enough to cause damage. …”

   NHTSA complaint #10293469, filed 2009-11, 28,289 miles

   “The contact owns a 2003 Workhorse w-22. The contact stated that he received a recall notice for recall 09v110000 (service brakes, hydraulic). The vehicle was repaired according to the recall and the contact was informed that the rotors had cracked due to the heat generated from the failed calipers. The dealer stated that even though the rotors were a part of the braking system, they would not be repaired under the recall. The failure mileage was 42,000.”

   NHTSA complaint #10376408, filed 2011-01, 42,000 miles

Buying note. Budget for a thorough brake inspection on any coach of this year, including rotors, calipers, sensors and fluid, and get the recall repair status in writing before purchase. Complaints show brake work on these chassis can be costly and sometimes repeated, so service records matter as much as mileage.

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.