2004 Workhorse CHASSIS problems and owner complaints
Explore the records behind recurring owner reports.
Key facts
34 owner complaints analyzed
1 distinct recall campaigns
17,000 mi median reported failure mileage
Scope: 2004 model year. Data snapshot: . 28 complaints include usable failure mileage.
Most common problems
Service Brakes, Hydraulic is the most frequently named component, appearing in 24 of 34 complaints (70.6%). A complaint can name multiple components.
| Topic | Matching reports | Share of complaints |
|---|---|---|
| Braking behavior | 28 | 82.4% |
| Electrical and battery issues | 2 | 5.9% |
| Engine operation | 1 | 2.9% |
| Steering behavior | 1 | 2.9% |
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 | 24 |
| Electrical System | 5 |
| Service Brakes, Hydraulic:Foundation Components:Disc:Caliper | 2 |
| Engine | 1 |
| Engine And Engine Cooling | 1 |
| Engine And Engine Cooling:Engine | 1 |
| Fuel System, Gasoline | 1 |
| Parking Brake | 1 |
Service Brakes, Hydraulic: 24; Electrical System: 5; Service Brakes, Hydraulic:Foundation Components:Disc:Caliper: 2; Engine: 1; Engine And Engine Cooling: 1; Engine And Engine Cooling:Engine: 1; Fuel System, Gasoline: 1; Parking Brake: 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 | 20 |
| 25,000 to 49,999 | 7 |
| 50,000 to 74,999 | 1 |
| 75,000 to 99,999 | 0 |
| 100,000 to 149,999 | 0 |
| 150,000 and above | 0 |
Under 25,000: 20; 25,000 to 49,999: 7; 50,000 to 74,999: 1; 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 (20). 6 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 |
|---|---|
| 2004 | 1 |
| 2005 | 3 |
| 2006 | 1 |
| 2007 | 1 |
| 2008 | 4 |
| 2009 | 5 |
| 2010 | 16 |
| 2016 | 1 |
| 2017 | 1 |
| 2019 | 1 |
2004: 1; 2005: 3; 2006: 1; 2007: 1; 2008: 4; 2009: 5; 2010: 16; 2016: 1; 2017: 1; 2019: 1
Pattern summary
Service Brakes, Hydraulic leads the component reports. Braking behavior appears in 28 complaint narratives. Electrical and battery issues appears in 2 complaint narratives. Engine operation 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.
Complaint evidence
Examples provide context, not a representative sample or a verified diagnosis.
Owner report 10138878 · 2005-10-05 (October 5, 2005)
CONSUMERS BRAKES WERE NOT RELEASING ALL THE WAY CAUSING MOTORHOME TO DRAG. *TS THE CONSUMER WAS UNABLE TO GET THE MOTORHOME TO REACH 55 MPH SO HE COULD USE THE OVER DRIVE. WHILE DRIVING , THE CONSUMER NOTICED THE BAS LIGHT HAD ILLUMINATED. THE CONSUMER REALIZED THERE WAS A SERIOUS BRAKE PROBLEM WHEN HE HAD TROUBLE STOPPING AND THEN HAD TROUBLE PULLING AWAY FROM IT. WHEN THE CONSUMER PULLED OVER, HE NOTICED OIL RUNNING OUT OF THE RIGHT FRONT HUB AND ALL 4 BRAKES WERE SMOKING, THE BRAKES HAD LOCKED UP AND THE CONSUMER HAD DIFFICULTY GETTING TH…
Owner-reported narrative. Look up ODI 10138878 at NHTSA ↗
Owner report 10202766 · 2007-09-12 (September 12, 2007)
TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING 25 MPH, THE CONTACT DISCOVERED THAT THE BRAKES WERE BURNING. THE CALIPERS BECAME SO HOT, THAT THE ABS SENSOR FAILED. THE CALIPER, ABS SENSOR, AND BRAKE PADS WERE ALL REPLACED AT THE COST OF $1,539.04. THE CURRENT MILEAGE WAS 20,000 AND FAILURE MILEAGE WAS 17,000. UPDATED 12-12-07. *KB UPDATED
Owner-reported narrative. 17,000 miles reported. Look up ODI 10202766 at NHTSA ↗
Owner report 10325419 · 2010-04-13 (April 13, 2010)
TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. THE CONTACT STATED THAT THE VEHICLE WAS REPAIRED ACCORDING TO RECALL 04V195000 (ELECTRICAL SYSTEM) AND RECEIVED A RECALL NOTICE FOR A BRAKE SYSTEM DEFECT (NOT IN NHTSA DATABASE): BOSCH CAMPAIGN ID:50901-C. THE CONTACT WAS DRIVING AT APPROXIMATELY 45 MPH WHEN THE BRAKE PEDAL STUCK SUDDENLY. THE CONTACT ALSO NOTICED A LOT OF HEAT BEING EMITTED FROM THE BRAKES AND SMOKE FROM THE WHEELS SO HE REMOVED THE PADS FROM THE ROTORS AND DROVE HOME. THE BRAKES DID NOT RETRACT SO THE ROTORS OVERHEATED INTERMITTEN…
Owner-reported narrative. 30,000 miles reported. Look up ODI 10325419 at NHTSA ↗
Owner report 10893108 · 2016-08-04 (August 4, 2016)
DRIVING DOWN 295@ 70 MPH , ENGINE DIED, LOST POWER STEERING, BRAKES, ALL ELECTRICAL. DEAD IN THE WATER, NEEDED TO TOW. I UNDERSTAND THAT THIS IS A PROBLEM WITH THIS CHASSIS. APPARENTLY THE IGNITION SWITCH MOUNTED ON THE STEERING COLUMN BURNS OUT BECAUSE IT IS OVERLOADED. WORKHORSE OFFERS A FIX USING RELAY COSTS OVER $300.00, SO THEY MUST REALIZE IT IS A PROBLEM.
Owner-reported narrative. 35,000 miles reported. Look up ODI 10893108 at NHTSA ↗