Workhorse Chassis Motorhome Club



President
Michael Pelchat
Michael Pelchat

 


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Recalls

 

Workhorse Safety Recalls

 

Recalls are published by Workhorse on a voluntary basis to address component failures that have immediate consequence to life and health.  If not complied with, loss of control, fire or other hazardous situations may prersent if the recall is not immediately addressed.  The NHTSA case number and or non compliance items VMVSS may be quoted in the recalls.  These repairs typically do not have an end date and will typically remain open until resolved at no cost to the owner.  Recalls are also known as Campaigns.  On completion of the campaign, a yellow campaign completion label is afixed to the vehilce.  Mine are located on the vertical strut that supports the Bosch Hydro-Max in the engine compartment.

 

20601-C Steering Intermediate Shaft

On some chassis, an incorrect steering shaft may have been installed during production. If an incorrect shaft is installed on your vehicle, it could cause the shaft to become loose at the steering box during tight steering maneuvers (e.g., while the vehicle is stopped or at very low speeds). If this occurs, steering control could be lost, possibly resulting in a vehicle crash. The purpose of this recall is to inspect the shaft on your vehicle and replace it if necessary.

 

20801-C Steering Arm Castle Nut

The Steering Arm Castle Nut affected a number of 2006 to 2008 W18 model motorhomes.  Please open the document to read the details.

 

30101-C Rear Axle U-Bolt Torque

Continued durability testing at our suspension supplier has revealed a possible high mileage durability issue on a limited number of rear spring front hanger brackets used on subject models. The lab durability testing revealed that hanger bracket could fail at high mileages past the normal warranty period. Since the spring eyebolt is attached directly to the frame, a failure of this bracket would not result in spring separation from the frame. It could result in the frame dropping down resulting in a vehicle leaning condition, but would not cause a risk to motor vehicle safety. The hanger bracket has been redesigned from a four bolt to six-bolt design to prevent the possible durability condition and the new bracket has entered production. However, 102 units were shipped with the early style rear spring front hanger bracket with four bolt holes. Workhorse Custom Chassis and our supplier have decided that Workhorse Customers should not be responsible for any problems with the bracket that could occur past normal warranty. Therefore, this bulletin authorizes and recommends that the four bolt brackets be changed to the improved six-bolt bracket while vehicles are still under warranty. This action is taken to maintain and increase customer confidence in the Workhorse chassis.

 

30501-T Rear Spring Front Hanger Bracket

Continued durability testing at our suspension supplier has revealed a possible high mileage durability issue on a limited number of rear spring front hanger brackets used on subject models. The lab durability testing revealed that hanger bracket could fail at high mileages past the normal warranty period. Since the spring eyebolt is attached directly to the frame, a failure of this bracket would not result in spring separation from the frame. It could result in the frame dropping down resulting in a vehicle leaning condition, but would not cause a risk to motor vehicle safety. The hanger bracket has been redesigned from a four bolt to six-bolt design to prevent the possible durability condition and the new bracket has entered production. However, 102 units were shipped with the early style rear spring front hanger bracket with four bolt holes. Workhorse Custom Chassis and our supplier have decided that Workhorse Customers should not be responsible for any problems with the bracket that could occur past normal warranty. Therefore, this bulletin authorizes and recommends that the four bolt brackets be changed to the improved six-bolt bracket while vehicles are still under warranty. This action is taken to maintain and increase customer confidence in the Workhorse chassis.

 

50401-C Bosch Brake Recall

Workhorse Custom Chassis has decided that a defect, which relates to motor vehicle safety, exists in certain 2001, 2002 and 2003 Workhorse W series chassis built with Bosch brake calipers.  The defect involves a brake caliper hanging in a partial apply position. A caliper in a partial apply position can overheat, causing damage. The brake system anti-lock feature may be lost if heat damages the anti-lock wheel sensor. There could also be a loss of brake performance.  Workhorse Custom Chassis is conducting a safety recall campaign to apply the Bosch repair remedy to involved vehicles.

 

50402-C Actia Instrument Cluster

Workhorse Custom Chassis has decided that a non-compliance with Federal Motor Vehicle Safety Standards (FMVSS) 101 and 105, which relates to motor vehicle safety, exists in certain subject models with Actia Instrument cluster. The non-compliances involve incorrect software programmed into the cluster such that certain driver warnings required by Federal Motor Vehicle Safety Standards (FMVSS) are not displayed. Incorrect software may not have the ability to illuminate warning lamps indicating brake system failure codes. FMVSS require   river warning when brake failure codes are set.

 

51101-C Bosch Brake Caliper Service Bulletin - Replacement of Bosch Service Brake Calipers

Workhorse Custom Chassis (Workhorse) has decided that a defect which relates to motor vehicle safety exists in the Bosch ZOPS and ZOHT slide-pin hydraulic disc brake systems. These service brake systems were installed on the Workhorse incomplete vehicle chassis identified below and were subsequently used in the manufacturing of motor homes. The pistons inside the brake caliper may stick in the applied position. If this were to occur, the service brakes may overheat - which may result in damage to other brake components and possibly lead to brake fluid boiling during normal operating conditions. If conditions described above were to occur, the performance of the service brakes may be reduced and the brake pedal may feel “soft” or “spongy.” Anticipated braking distance may also increase which may result in a crash that may cause property damage, personal injury, or death.

 

60001-C Incorrect Evaporative Emissions label installed on radiator fan shroud

Workhorse Custom Chassis has determined that certain model year 1999 and 2000 gasoline powered units were shipped with an incorrect evaporative emission control label. The 1999 models were built with year 2000 engine certifications. This condition must be corrected by installing the correct label over top of the incorrect label located on the radiator fan shroud. (Figure 1) The incorrect labels (Part no. 12560938 or 12538582) are shown by figures 2 and 3. The correct label (Part no.15755820) is to be installed over the incorrect label shown by figure 4.

 

60201-C INCORRECT EMISSIONS LABEL-CALIFORNIA

Workhorse Custom Chassis has determined that certain 2001 model year vehicles were sent to California with Federal emission labels. This condition must be corrected by removing the Federal label and installing the California label on the vehicle engine and radiator frame. The correct label for California vehicles is part number 12568572 and is shown by Figure 1. This label must be installed on involved vehicles. The Federal label is part number 12565672 and is shown by Figure 2. This label must be removed from involved vehicles operating in California.

 

60202-C Post (Rear) Oxygen Sensors Cross Wired

Workhorse Custom Chassis is conducting a Voluntary Emission Recall involving 2001, 2002, and 2003 models with 5.7L (350CID RPO L31 VIN Code R) engine to correct cross-wired oxygen (O2)sensors. The left O2 sensor is incorrectly wired to the harness that goes to the right sensor at ECM and right sensor is incorrectly wired to harness that goes to left sensor location at ECM. (Cross-wired)

 

60301-C INCORRECT ENGINE EMISSIONS LABEL-50 STATE

Workhorse Custom Chassis has determined that certain 2003 model chassis with L18 8.1L engine were built with an incorrect 50 State Engine Emissions label. This condition must be corrected by removing the incorrect label part number 12575757 and installing the correct label part number W0005452.

 

60401-C Incorrect Catalytic Converter

Workhorse Custom Chassis has determined that certain model year 2003 motorhome chassis with option L18- 8.1L Vortec gasoline engine were built with an incorrect Catalytic Converter. This condition must be corrected by replacing the catalytic converter assembly as outlined by instructions.

 

60601-C Engine Fuel Rail Damper Retainer Clip

Workhorse Custom Chassis has determined that a defect, which relates to motor vehicle safety, may exist in 2004, 2005 and certain 2006 Workhorse models with 8.1 L gasoline engine. The defect involves an improperly heat treated fuel rail damper retainer clip that may have been installed on the subject engines. An improperly heat treated clip may break, possibly resulting in a gasoline leak at the fuel rail damper. A vehicle fire can result if the leaking fuel is ignited by a spark or flame. A defective clip can not be confirmed by a visual inspection. Therefore, Workhorse Custom Chassis is conducting a safety recall campaign to replace the fuel rail damper retaining clip on all units involved.

 

60901-CS Electric Fan Clutch and Water Pump Replacement

It has been determined that the electronic fan clutch installed on the UFO chassis identified above may not disengage as intended and may result in excessive stress on the water pump shaft. Consequently, some or all of the following may occur:- Water pump leak,- Water pump shaft failure, and- Engine overheating Workhorse Custom Chassis (Workhorse) is issuing this customer satisfaction notice authorizing the installation of a redesigned electronic fan clutch and water pump for the affected UFO chassis.

 

61101-C Replacement of Fuel Tank Fill Cap, Unused Fill Inlet on 75-and 100-Gallon Gasoline Fuel Tanks (Option Codes NDF and NNB)

Workhorse Custom Chassis (Workhorse) has decided that a defect which relates to motor vehicle safety exists in certain W-series and R-series motorhome chassis built from February 5, 2007, through May 24, 2010, and equipped with either the 75-gallon or 100-gallon gasoline dual fill fuel tanks. The fuel-fill cap assemblies used to seal the unused fuel tank inlet was produced with a hose material that did not meet design specification. During normal usage the hose material may deteriorate which can result in a fuel leak. A fuel leak increases the risk of a fire which may result in property damage, personal injury, or death.

 

80101-C Remy Inc. “Remy” Alternator Verification and Replacement

It has been determined that certain alternators manufactured by Remy, Inc. (“Remy”) may develop an electrical short when the battery cables are connected, or during operation, which can result in a fire originating in the alternator.

 

There are other recalls that pretain to commercial vehilces however those were intentionally not included here. 

 

 

 

 

 

  

 



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