2003 Coachmen AURORA: complaints, problems and recalls

TL*THE CONTACT OWNS A 2003 COACHMEN AURORA. WHILE DRIVING 45 MPH, THE BRAKE PEDAL EXTENDED TO THE FLOORBOARD WHEN IT WAS DEPRESSED. THE FAILURE CAUSED THE STOPPING DISTANCE TO INCREASE. THE MECHANIC STATED THAT THE PASSENGER SIDE FRONT CALIPER LOCKED. HE REPLACED THE CALIPERS, BRAKE PADS, AND THE ABS SENSOR. THERE HAD BEEN NO FURTHER OCCURRENCES. NHTSA CAMPAIGN ID NUMBER 04V518000 (SERVICE BRAKES, HYDRAULIC: FOUNDATION COMPONENTS: DISC: CALIPER) WAS REFERENCED. THE FAILURE MILEAGE WAS 13,500 AND CURRENT MILEAGE WAS 15,200.

Owner-reported narrative. 13,500 miles reported. Look up ODI 10202025 at NHTSA ↗

REAR BRAKES ON 2003 COACHMEN ON WORKHORSE CHASSIS OVERHEATED AND LOCKED UP CAUSING NO BRAKES WHILE GOING DOWN FREEWAY. *TR

Owner-reported narrative. 29,000 miles reported. Look up ODI 10216676 at NHTSA ↗

THERE WAS SMOKE COMMING OUT FROM UNDER THE FRONT OF MY MOTOR HOME. TOOK TO A SHOP WHERE THEY TOLD ME THAT THE BRAKE CALIPERS ON BOTH FRONT WHEELS HAD FROZEN UP CAUSING EVERYTHING TO OVER HEAT WHICH RESULTED IN MELTING THE SEALS FOR THE WHEEL BEARINGS LETTING THE OIL TO RUN OUT. THE ROTORS HAD TO BE MECHINED AND HE CALIPERS WERE REPLACED WITH REBUILT ONES. THEY ALSO REPLACED THE BRAKE HOSES.

Owner-reported narrative. 29,580 miles reported. Look up ODI 10226330 at NHTSA ↗

HAVE A COACHMEN 2003 RV ON A WORKHORSE W22 CHASSIS THAT THE FRONT BRAKE OVERHEATED AND LOCKED UP. *TR

Owner-reported narrative. 37,264 miles reported. Look up ODI 10246798 at NHTSA ↗

Reported: 2003-02-10 (February 10, 2003)

CERTAIN MOTOR HOME CHASSIS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." THE BRAKE SYSTEM WARNING INDICATOR MAY NOT FUNCTION AS REQUIRED BY STANDARD.

Consequence: IN SOME OF THE AFFECTED VEHICLES, THE BRAKE SYSTEM WARNING INDICATOR WILL NOT ILLUMINATE WHEN THE IGNITION IS IN THE START POSITION OR FOR A LOW BRAKE FLUID CONDITION, IF THE BODY BUILDER RELIED SOLELY UPON FORD'S IVM COMPLIANCE STATEMENT FOR THE BRAKE SYSTEM WARNING INDICATOR.

Remedy: DEALERS WILL REPAIR THE BRAKE WARNING LAMP CIRCUIT. OWNER NOTIFICATION BEGAN MARCH 24, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT COACHMEN AT 1-219-825-5821.

Reported: 2004-10-27 (October 27, 2004)

ON MOTOR HOME CHASSIS BUILT BY WORKHORSE AND EQUIPPED WITH BOSCH BRAKES, THE PADS CAN DRAG ON THE ROTOR SURFACE DUE TO THE PIN SLIDE.

Consequence: A HANG UP OR LOCK UP MAY CAUSE THE CALIPERS TO OVER HEAT AND NOT ALLOW THE DRIVER TO STOP SAFELY. THIS COULD CAUSE OVERHEATING OF THE BRAKE CALIPERS WHICH COULD RESULT IN A VEHICLE FIRE.

Remedy: WORKHORSE IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. DEALERS WILL REPAIR THE BRAKE CALIPER. OWNERS SHOULD CONTACT WORKHORSE AT 1-877-294-6773 OR COACHMEN AT 219-825-5821.

Reported: 2005-03-11 (March 11, 2005)

ON CERTAIN MOTOR HOMES BUILT ON WORKHORSE CHASSIS, FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 101, "CONTROLS AND DISPLAY" AND STANDARD NO. 105 "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." MODELS WITH ACTIA INSTRUMENT CLUSTER, THE INCORRECT SOFTWARE PROGRAMMED INTO THE CLUSTER SUCH THAT CERTAIN WARNINGS ARE NOT DISPLAYED.

Consequence: INCORRECT SOFTWARE MAY NOT HAVE THE ABILITY TO ILLUMINATE WARNING LAMPS INDICATING BRAKE SYSTEM FAILURES. THE STANDARDS REQUIRE DRIVER WARNING WHEN BRAKE FAILURE CODES ARE SET.

Remedy: WORKHORSE IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. OWNERS MAY CONTACT WORKHORSE AT 1-877-294-6773 OR COACHMEN AT 574-825-5821.

Reported: 2009-06-02 (June 2, 2009)

COACHMEN IS RECALLING 2,555 MY 2000-2009 GEORGIE BOY AND COACHMEN RECREATIONAL TRAILERS EQUIPPED WITH AXLES THAT INCLUDE BOSCH ZOPS OR ZOHT PIN SLIDE HYDRAULIC DISC BRAKES. WHEN COMBINED WITH OCCASIONAL OR SEASONAL VEHICLE OPERATION MAY EXPERIENCE CALIPERS STICKING IN THE APPLIED POSITION. THIS CAN RESULT IN ABNORMAL HEAT GENERATION AT THE WHEEL END CAUSING BRAKE DRAG. THE DRIVER WOULD NORMALLY HAVE WARNING OF THE BRAKE DRAG IF UNDETECTED BY THE DRIVER.

Consequence: THE DRIVER WOULD NORMALLY DETECT THE BRAKE DRAG BUT IF UNDETECTED THE TEMPERATURE INCREASE AT THE WHEEL END CAN EVENTUALLY LEAD TO SOFT PEDAL CONDITIONS DUE TO BRAKE FLUID BOIL, AND POSSIBLE EXTENDED STOPPING DISTANCE INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT AND REPLACE THE NECESSARY COMPONENTS FREE OF CHARGE. WORKHORSE IS HANDLING THE REMEDY FOR THIS CAMPAIGN PLEASE SEE 09V-110. THE MANUFACTURER HAS NOT YET PROVIDED AN OWNER NOTIFICATION SCHEDULE. OWNERS MAY CONTACT WORKHORSE AT 1-877-246-7731 OR COACHMEN AT 1-574-266-4030, option 5.