2004 Workhorse W20: complaints, problems and recalls
Explore the records behind recurring owner reports.
Key facts
7 owner complaints analyzed
2 distinct recall campaigns
18,850 mi median reported failure mileage
Scope: 2004 model year. Data snapshot: . 6 complaints include usable failure mileage.
Most common problems
Service Brakes, Hydraulic is the most frequently named component, appearing in 3 of 7 complaints (42.9%). A complaint can name multiple components.
| Topic | Matching reports | Share of complaints |
|---|---|---|
| Braking behavior | 6 | 85.7% |
| Transmission and shifting | 1 | 14.3% |
| Steering behavior | 1 | 14.3% |
Topic matches use published keyword rules. They describe mentions, including negations or comparisons, and do not confirm a diagnosis. Read the matching rules.
Component breakdown
Number of unique complaints naming each component. Top eight shown.
| Category | Count |
|---|---|
| Service Brakes, Hydraulic | 3 |
| Electrical System: Instrument Cluster/Panel | 1 |
| Service Brakes, Hydraulic:Antilock/Traction Control/Electronic Limited Slip | 1 |
| Service Brakes, Hydraulic:Antilock/Traction Control/Electronic Limited Slip:Abs Warning Light | 1 |
| Service Brakes, Hydraulic:Foundation Components:Disc:Caliper | 1 |
| Service Brakes, Hydraulic:Foundation Components:Disc:Rotor | 1 |
| Service Brakes, Hydraulic:Foundation Components:Drum:Wheel Cylinders | 1 |
| Visibility | 1 |
Service Brakes, Hydraulic: 3; Electrical System: Instrument Cluster/Panel: 1; Service Brakes, Hydraulic:Antilock/Traction Control/Electronic Limited Slip: 1; Service Brakes, Hydraulic:Antilock/Traction Control/Electronic Limited Slip:Abs Warning Light: 1; Service Brakes, Hydraulic:Foundation Components:Disc:Caliper: 1; Service Brakes, Hydraulic:Foundation Components:Disc:Rotor: 1; Service Brakes, Hydraulic:Foundation Components:Drum:Wheel Cylinders: 1; Visibility: 1
Reported problems by failure mileage
Complaint counts in mileage bands. These are not failure rates per vehicle or mile.
| Category | Count |
|---|---|
| Under 25,000 | 4 |
| 25,000 to 49,999 | 2 |
| 50,000 to 74,999 | 0 |
| 75,000 to 99,999 | 0 |
| 100,000 to 149,999 | 0 |
| 150,000 and above | 0 |
Under 25,000: 4; 25,000 to 49,999: 2; 50,000 to 74,999: 0; 75,000 to 99,999: 0; 100,000 to 149,999: 0; 150,000 and above: 0
Under 25,000 miles has the most reports with usable mileage (4). 1 complaints have missing, zero or invalid mileage.
Complaints over time
Year the complaint was filed, not the vehicle model year or incident year. The snapshot year is partial.
| Category | Count |
|---|---|
| 2007 | 2 |
| 2008 | 4 |
| 2009 | 1 |
2007: 2; 2008: 4; 2009: 1
Pattern summary
Service Brakes, Hydraulic leads the component reports. Braking behavior appears in 6 complaint narratives. Transmission and shifting appears in 1 complaint narratives. Steering behavior appears in 1 complaint narratives. Use these patterns to inspect individual reports and prepare questions for a mechanic.
Calculated from recorded counts. An AI narrative has not been published for this selection.
Examples from the source records
Examples provide context, not a representative sample or a verified diagnosis.
Owner report 10201868 · 2007-09-04 (September 4, 2007)
DRIVING RV NORMALLY ABOUT 40 MPH WHEN REQUIRED TO STOP. BRAKE PEDAL WENT TO THE FLOOR. PUMPED VIGOROUSLY AND GOT A SMALL AMOUNT OF PEDAL. WHEN UNIT COOLED, WAS ABLE TO DRIVE SLOWLY FOR REPAIR. LEFT REAR ROTOR WAS SCORED AND THE CALIPER WAS STICKING, CAUSING THE BRAKE FLUID TO BOIL. *JB UPDATED 12/12/07 *BF UPDATED 12/12/07 *TR
Owner-reported narrative. 10,506 miles reported. Look up ODI 10201868 at NHTSA ↗
Owner report 10202938 · 2007-09-13 (September 13, 2007)
THIS IS A BRAKE FAILURE ON ,MY 2004 ALLEGRO MOTORHOME BUILT ON A W-20 CHASSIS MANUFACTURED BY WORKJORSE CUSTOM CHASSIS. ON THE DATE IN QUESTION, THE RIGHT REAR BRAKE LOCKED UP AND OVERHEATED. THE LEFT REAR BRAKE OVERHEATED. THESE ACTIONS CAUSED REPLACEMENT OF THE RIGHT REAR CALIPER, ROTER, SEALS AND SLIDE PINS. THE CALIPER AND SLIDE PINS WERE REPLACED ON THE LEFT REAR BRAKE. THE CALIPERS AND SLIDE ON BOTH FRONT BRAKES WERE REPLACED DUE TO OVERHEATING. OLD PARTS ARE AVAILABLE FOR INSPECTION. THE WORK WAS PERFORMED AT AN AUTHORIZED WORKHORSE…
Owner-reported narrative. 20,100 miles reported. Look up ODI 10202938 at NHTSA ↗
Owner report 10216819 · 2008-02-03 (February 3, 2008)
RIGHT FRONT DISC BRAKE OVERHEATED AND CAUSED OIL SEAL FAILURE RESULTING IN CONTAMINATION OF DISC BRAKE LINING CONTAMINATION AND REDUCED BRAKE EFFECTIVENESS. *TR
Owner-reported narrative. 17,600 miles reported. Look up ODI 10216819 at NHTSA ↗
Owner report 10217086 · 2008-02-06 (February 6, 2008)
THE BRAKES WERE FADING SO I HAD THEM INSPECTED BY LES SCHWAB TIRES. THEY INFORMED ME THAT ALL 4 ROTORS HAD CRACKS IN THEM AND THEY WERE A SAFETY ISSUE. I HAVE ABOUT 30,000 MILES ON THE 2004 SOUTHWIND MOTORHOME WORKHORSE CHASIS. I AM RESPONDING TO NHTSA ACTION NUMBER: EA07016. *TR
Owner-reported narrative. 30,000 miles reported. Look up ODI 10217086 at NHTSA ↗
Owner report 10243450 · 2008-09-25 (September 25, 2008)
ON 9/6/07, THE L.F. BRAKE ON MY MOTORHOME SEIZED UP AND OVERHEATED THE BRAKE ROTOR FOR ALMOST 10 MILES UNTIL I NOTICED SEVERE SHAKING IN THE STEERING WHEEL & SMELLED "BURNT BRAKE LINING" WHEN I STOPPED. I WAS DRIVING IN NORMAL CITY TRAFFIC NEAR ALLIANCE, OHIO; -NOT EXCESSIVE STOP AND GO, BUT THERE WAS MAYBE 4 RED LIGHTS OVER THE COURSE OF 3 MILES DISTANCE (AT 30 MPH) TO STOP. MY STOPPING WAS "NORMAL", NOT SUDDEN OR ERRATIC. THE LEFT FRONT HUB & WHEEL GOT SO HOT FROM THE CALIPER/BRAKE ASSY. SEIZING THAT IT BOILED AWAY ALL OF THE 90W LUBE ON …
Owner-reported narrative. 10,920 miles reported. Look up ODI 10243450 at NHTSA ↗
Owner report 10247194 · 2008-10-29 (October 29, 2008)
WHILE DRIVING ON US441 NEAR TAVARES FL GOT A WARNING LIGHT FOR ANTI LOCK BRAKES. PULLED OVER INTO A SHOPPING AREA. LEFT FRONT WHEEL AND RIGHT REAR DUAL WHEEL WERE HOT. RESTARTED ENGINE GOT A BRAKE FAILURE WARNING ON DASH MESSAGE CENTER. LET BRAKES COOL FOR APPROXIMATELY 90 MINUTES. DROVE HOME THEN TO WORKHORSE REPAIR CENTER WITHOUT FURTHER TROUBLE. COURTESY CHEVROLET REPLACED 4 ROTORS 4 CALIPERS 2 ANTI LOCK SENSOR AND REPLACED BRAKE FLUID. *TR
Owner-reported narrative. 38,133 miles reported. Look up ODI 10247194 at NHTSA ↗
Owner report 10275057 · 2009-06-26 (June 26, 2009)
WE DO NOT FEEL THAT THE INSTRUMENT PANEL CLUSTER ON OUR MOTORHOME HAS EVER BEEN LARGE ENOUGH OR CLEAR ENOUGH FOR EASY READING. WE HAVE ALWAYS BEEN UNHAPPY WITH THE VISIBILITY AND JUST RECENTLY THE TRANSMISSION INDICATORS FOR 3 AND 1 GEAR HAVE FADED COMPLETELY. AT PRESENT WE HAVE AN APPOINTMENT TO GET THE PANEL REPLACED. *TR
Owner-reported narrative. Look up ODI 10275057 at NHTSA ↗
Recall history
2 distinct campaigns affect this selection. Announcement dates below are different from vehicle model years. A campaign may cover multiple years.
06V225000 · Engine And Engine Cooling
Reported: 2006-06-20 (June 20, 2006)
ON CERTAIN MOTOR HOME AND TRUCK CHASSIS EQUIPPED WITH GENERAL MOTORS 8.1L V8 ENGINES, IMPROPER HARDENING DURING THE HEAT TREATMENT PROCESS CAN CAUSE THE FUEL RAIL PULSE DAMPER RETAINER CLIP TO FRACTURE, RESULTING IN INADEQUATE RETENTION OF THE DAMPER. IF THE DAMPER BECOMES LOOSE, FUEL COULD BE PUMPED BY THE FUEL PUMP INTO THE UNDER HOOD AREA.
Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.
Remedy: DEALERS WILL REPLACE THE FUEL RAIL PULSE DAMPER RETAINER CLIPS ON THESE ENGINES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 1, 2006. OWNERS MAY CONTACT WORKHORSE AT 877-294-6773.
NHTSA campaign record ↗09V110000 · Service Brakes, Hydraulic
Reported: 2009-04-03 (April 3, 2009)
NAVISTAR IS RECALLING CERTAIN MODEL YEAR MY 2001-2008 WORKHORSE W20, W21 AND W22 CHASSIS AND CERTAIN MODEL YEAR 2009 THROUGH 2011 MONACO RV ADMIRAL, ARISTA, MONARCH, AND RIPTIDE RECREATIONAL VEHICLES 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 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: WORKHORSE DEALERS WILL REPLACE ALL FOUR BOSCH BRAKE CALIPER ASSEMBLIES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 16, 2010. OWNERS MAY CONTACT WORKHORSE AT 1-877-246-7731.
NHTSA campaign record ↗