2004 Workhorse W22 Service Brakes, Hydraulic Problems

Source: NHTSA · Updated Jul 6, 2023 · 74 complaints analyzed

Owners have filed 74 complaints with NHTSA about service brakes, hydraulic problems on the 2004 Workhorse W22, 80% of all complaints for this model year. Half of the reports with a mileage happened before 21,652 miles. The words owners use most often: “motor home” (23% of reports).

What owners describe

Phrases that appear unusually often in these complaints compared with complaints about other cars.

  • Motor home: mentioned in 17 of 74 complaints (23%)
  • Chassis consumer: mentioned in 12 of 74 complaints (16%)
  • Pace arrow: mentioned in 8 of 74 complaints (11%)
  • Brake calipers: mentioned in 6 of 74 complaints (8%)

At what mileage do service brakes, hydraulic problems happen?

Based on 48 complaints that reported the odometer reading.

Under 10k miles4 · 8%
10k–25k miles30 · 63%
25k–50k miles14 · 29%
50k–75k miles0 · 0%
75k–100k miles0 · 0%
100k–150k miles0 · 0%
150k+ miles0 · 0%

How serious are the reports?

Of 74 complaints, 2 a fire.

Workhorse W22 service brakes, hydraulic complaints by model year

Peak: 2003, with 106 complaints
2000: 1200012001: 9200192002: 622002622003: 10620031062004: 742004742005: 182005182006: 7200672007: 3200732008: 320083

n = 283 complaints · Source: NHTSA

Model yearService Brakes, Hydraulic complaintsShare of that yearMedian miles
2008 W22375%12,900
2007 W22360%—
2006 W22788%16,500
2005 W221886%13,940
2004 W227480%21,652
2003 W2210694%22,000
2002 W226293%28,147
2001 W22990%27,000
2000 W221100%31,252

When owners reported it

Peak: 2009, with 24 complaints
2004: 1200412006: 1200612007: 1200712008: 192008192009: 242009242010: 172010172011: 8201182018: 1201812022: 1202212023: 120231

n = 74 complaints · Source: NHTSA

Related recalls (1)

Service brakes, hydraulicApr 3, 2009 · NHTSA campaign 09V110000 · 48,876 vehicles

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.

What owners report

Short excerpts of recent complaints, with personal details removed. Full reports are on NHTSA.gov.

The contact owns a 2004 Workhorse W22. The contact stated that after the RV was stored for several years, the contact learned that the brakes had seized. The contact then became aware that the RV was included in a recall. The RV was taken to the dealer and repaired under NHTSA Campaign Number…

Received Jul 6, 2023 · NHTSA complaint 11530594

The contact owns a 2004 Newmar Kountry built on a 2004 Workhorse W22 chassis. The contact stated while driving 70 MPH, the brake pedal was depressed but failed to respond as needed. The contact was able to continue driving. The vehicle was taken to an independent mechanic on four occasions where…

Received Sep 7, 2022 · NHTSA complaint 11483385

2004 chevrolet gulf stream. Consumer writes in regards to brake system recall repair issues - right front caliper/abs sensor replacements. *smd *tr

Received Apr 3, 2018 · NHTSA complaint 10917053

Frequently asked questions

Do all 2004 Workhorse W22s have service brakes, hydraulic problems?

No. NHTSA has 74 owner complaints about service brakes, hydraulic for the 2004 Workhorse W22 (80% of the 92 complaints for this model year). Complaint data shows that the problem is reported, not how many of all cars sold are affected.

Was there a recall on the 2004 Workhorse W22 service brakes, hydraulic?

Yes: 1 safety recall list service brakes, hydraulic. Check your VIN on NHTSA.gov to see whether the fix was done on your car.

At what mileage do service brakes, hydraulic problems start?

The median reported mileage is 21,652 miles: half of the reports with a mileage came before that.

What do owners say about service brakes, hydraulic problems on the 2004 Workhorse W22?

The most frequent phrase is “motor home”, in 17 of 74 complaints, followed by “chassis consumer” (12).

See all 2004 Workhorse W22 problems or service brakes, hydraulic problems across all W22 years.