- The 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.
- The 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.
- The 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.
Vehicle safety record
2004 Workhorse W20 Problems, complaints & recalls
Owners have filed 7 complaints about the 2004 Workhorse W20 with NHTSA, most often about the brakes (6) and the electrical system (1). It is covered by 2 recalls, the latest in April 2009 for the service brakes, hydraulic. For comparison, the 2003 has 11 and the 2005 has 3.
NHTSA data checked
CAbout as many problems as a typical W20 year, for its age
#240 most complained-about 2004 vehicle
- Complaints
- 7
- Recalls
- 2
- Crashes
- 0
- Fires
- 0
- Injuries
- 0
- Deaths
- 0
Most common 2004 Workhorse W20 problems
Share of all 7 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.
2004 Workhorse W20 recalls 2
Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do
- The 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.
- The risk
- In the presence of an ignition source, a fire could result.
- The 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.
What owners say
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7 complaints about the 2004 Workhorse W20
Newest first, as filed with NHTSA by owners.
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
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
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...
Read the full complaint
boiled away all of the 90w lube on the wheel bearings and blew out the rubber plug on the lube sight glass. I let it cool down for an hour, then looked at the inner side of the l.F. Wheel to see if I'd have to loosen/pry away the seized brake pad or caliper assembly. Surprise, the brake pads were already sitting back away from the rotor; -the caliper had apparently retracted by itself after cooling down. I proceeded slowly to the campground, 5 miles away, and made arrangements to get some 90w lube oil. Lube was replaced the next day and the wheel bearings still felt good; another sight cap seal was installed. On 9/12/07, I took the coach to mainline truck & trailer (a workhorse chassis service dealer) in solon, ohio, for service. In a nutshell, I ended up paying $828.28 To repair the damage and service my coach for future "peace of mind". The following work was performed: serviced all caliper slide pins, lube, & boots on all 4 wheels; confirm correct caliper operation on all 4; replace abs wheel sensor on left front; reset abs warning light; inspect all 4 rotors for cracks; replace lf wheel bearing inner seal; inspect lf bearings; inspect rear axle hub seals; etc. On 9/18/08, at 11,891 miles, my right front brake seized up unexpectedly! This time along a 45 mph state hwy with very infrequent braking. I believe the problem here is faulty abs controller and or the bosch brakes. They do not always release the calipers. Workhorse ignores this problem! *Tr
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
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 service center and the coast can be provided upon request
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
Workhorse W20: every year compared
All W20 years2004 Workhorse W20 vs rivals
| Vehicle | Complaints | Recalls | Grade | |
|---|---|---|---|---|
| 2004 Workhorse W20 | 7 | 2 | C | |
| 2004 Workhorse W22 | 92 | 2 | F | Compare |
| 2004 Workhorse Chassis | 34 | 1 | - | Compare |
| 2004 Workhorse P32 | 2 | 1 | C | Compare |
More sales usually means more complaints, so compare similar vehicles of the same year. The grade compares each vehicle with its own model's other years.
Questions about the 2004 Workhorse W20
Does the 2004 Workhorse W20 have any recalls?
Yes - NHTSA lists 2 recalls for the 2004 Workhorse W20: service brakes, hydraulic (April 2009); engine and engine cooling (June 2006). Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.
What are the most common problems with the 2004 Workhorse W20?
By the complaints owners filed with NHTSA, the most common problem areas are the brakes (6), electrical system (1), visibility & wipers (1).
How many complaints has the 2004 Workhorse W20 had?
7 complaints have been filed with NHTSA, the first on September 4, 2007 and the latest on June 26, 2009. Of these, 0 describe a crash and 0 a fire, and together they report 0 injuries and 0 deaths.
Is the 2004 Workhorse W20 a reliable vehicle?
Its Safety Index is 44 out of 100 (grade C: about as many problems as a typical Workhorse W20 year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.
Which Workhorse W20 years have the most complaints?
2003 (11), 2004 (7), 2002 (6). See every Workhorse W20 year compared.
What should I do if my 2004 Workhorse W20 has a problem?
If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data