2004 Workhorse W20 Problems, Complaints & Recalls
- Compared with other W20 years
- Not enough data 2nd of 9 for complaints
- Safety recalls
- 2 recalls: check your VIN
- NHTSA crash rating
- Not rated
Owners have filed 7 complaints with NHTSA about the 2004 Workhorse W20. That ranks 2nd out of 9 W20 model years for complaints. The most reported problem area is service brakes, hydraulic (6 complaints, 86%), typically at around 18,850 miles. There are 2 safety recalls covering this model year. NHTSA has opened 2 defect investigations involving it.
- 7owner complaints
- 2safety recalls
- 2NHTSA investigations
- 0complaints mentioning a crash
Complaints are unverified owner reports and are not adjusted for sales volume.
Most common 2004 Workhorse W20 problems
Complaints grouped by the part of the car owners reported, with the median mileage when the problem happened.
| Problem area | Complaints | Share | Median miles | Owners mention most | Typical repair cost |
|---|---|---|---|---|---|
| Service Brakes, Hydraulic | 6 | 86% | 18,850 | — | — |
| Electrical System | 1 | 14% | — | — | — |
| Visibility | 1 | 14% | — | — | — |
| Wheels | 1 | 14% | 10,920 | — | — |
One complaint can list several problem areas, so shares can add up to more than 100%.
Complaints by year received
2004 Workhorse W20 recalls (2)
Tap a recall to see the problem, the risk and the fix.
Service brakes, hydraulic
Problem: 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.
Risk: 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.
Fix: 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.
Engine and engine cooling
Problem: 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.
Risk: In the presence of an ignition source, a fire could result.
Fix: 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.
To see whether a specific car still has an open recall, enter its VIN on NHTSA's official recall lookup. You can also decode a VIN here.
NHTSA defect investigations
- Overheating disc brake caliper (EA07016) — opened Nov 16, 2007, closed Aug 19, 2009, led to recall 09V110000.
- Overheated brake calipers (PE07032) — opened Jun 25, 2007, closed Nov 19, 2007.
Recent owner reports
Short excerpts of the latest complaints filed with NHTSA, with personal details removed. Full reports can be searched on NHTSA.gov.
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…
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…
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…
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
Right front disc brake overheated and caused oil seal failure resulting in contamination of disc brake lining contamination and reduced brake effectiveness. *tr
Other Workhorse W20 years
| Year | Complaints | Recalls |
|---|---|---|
| 2008 W20 | 0 | 1 |
| 2007 W20 | 0 | 1 |
| 2006 W20 | 3 | 2 |
| 2005 W20 | 3 | 2 |
| 2004 | 7 | 2 |
| 2003 W20 | 11 | 1 |
| 2002 W20 | 6 | 2 |
| 2001 W20 | 2 | 3 |
| 2000 W20 | 1 | 1 |
See all Workhorse W20 problems by year, every Workhorse model, or the VIN decoder.
Similar Workhorse models
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Frequently asked questions
What are the most common problems with the 2004 Workhorse W20?
Owners most often report service brakes, hydraulic, electrical system, visibility problems. The top one, service brakes, hydraulic, accounts for 6 complaints.
Was there a recall on the 2004 Workhorse W20?
Yes, 2 safety recalls. Enter your VIN at NHTSA.gov to check whether the repairs were done on your car.
Was the 2004 Workhorse W20 a good year?
Complaint data can't fully answer that, because counts aren't adjusted for sales. Compared with other W20 model years, the 2004 has too little data to compare. Always get a pre-purchase inspection and check the VIN for open recalls.