RoadVitals

2004 Workhorse W20

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
7
Latest Jun 26, 2009
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
2
Latest Apr 3, 2009
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
2
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
0

Overview

Our database contains 7 NHTSA owner-reported complaints for the 2004 Workhorse W20, most frequently naming the brakes, electrical and other / unspecified categories. 2 safety recalls have been issued covering this model year; and 2 NHTSA investigations name it.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Brakes666.7%
  • Electrical111.1%
  • Other / unspecified111.1%
  • Visibility111.1%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

2 campaigns cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
09V110000

SERVICE BRAKES, HYDRAULIC

Apr 3, 2009
48,876 units potentially affected
The defect: 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 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.
NAVISTAR, INCManufacturer number 50901-C & 51101-CView on NHTSA.gov
06V225000

ENGINE AND ENGINE COOLING

Jun 20, 2006
30,335 units potentially affected
The defect: 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 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.
WORKHORSE CUSTOM CHASSISManufacturer number 60601-CView on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

EA07016ClosedEngineering Analysis

OVERHEATING DISC BRAKE CALIPER

Opened Nov 16, 2007
Closed Aug 19, 2009

THE EA WAS OPENED TO GAIN A TECHNICAL UNDERSTANDING OF THE CAUSES FOR ONE OR MORE DISC BRAKE CALIPERS ON A SUBJECT VEHICLE TO SUFFER SEVERE OVERHEATING. THE OVERHEATING CAUSED BRAKE DRAG, MELTING ABS SENSORS, SMOKING, BRAKE LINING FIRES, AND IN SOME CASES BOILING BRAKE FLUID RESULTING IN DIMINISHED STOPPING CAPABILITY.BASED ON TESTING, WARRANTY AND COMPLAINT DATA ANALYSIS, FIELD TRIPS AND INTERVIEWS WITH OWNERS, MECHANICS AND SERVICE MANAGERS, ODI BELIEVES THE LIKELY CAUSE OF THE ALLEGED DEFECT IS WATER SWELL OF THE PHENOLIC CALIPER PISTON AND SUBSEQUENT FAILURE OF THE PISTON TO FULLY RETURN AFTER THE PEDAL IS RELEASED.A TECHNICAL REPORT IS ATTACHED WITH FULL DETAILS.

SERVICE BRAKES, HYDRAULICLed to recall 09V110000
PE07032ClosedPreliminary Evaluation

OVERHEATED BRAKE CALIPERS

Opened Jun 25, 2007
Closed Nov 19, 2007

ON JUNE 25, 2007, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED OVERHEATING DISC BRAKE CALIPERS AND POOR BRAKE PERFORMANCE IN MODEL YEAR (MY) 2000-2005 WORKHORSE CHASSIS RECREATIONAL VEHICLES.CURRENTLY ODI IS AWARE OF 651 SPECIFIC COMPLAINTS ON THE SUBJECT VEHICLES (ODI AND WORKHORSE COMPLAINT POPULATION).ODI ANALYSIS OF THE WARRANTY AND COMPLAINT DATA FURNISHED BY WORKHORSE ON SEPTEMBER 11, 2007, IN RESPONSE TO ODI'S INFORMATION REQUEST INDICATES A DRAMATIC DROP IN BRAKE RELATED COMPLAINTS AFTER THE MAY 2004 BUILD DATE.AT THAT TIME, WORKHORSE INCORPORATED INTO PRODUCTION ZERK FITTINGS AND GREASING OF THE BRAKE MASTER CYLINDER'S BELL CRANK LINKAGE.ODI IS ALSO AWARE OF 3,782 UNIQUE WARRANTY COUNTS RELATED TO THE ALLEGED DEFECT IN THE SUBJECT POPULATION.A REVIEW OF THE WARRANTY CLAIMS REVEALS THAT OF THE CLAIMS FILED, ONLY 88 WERE SUBMITTED ON VEHICLES PRODUCED AFTER THE MAY 2004 PRODUCTION LINE CHANGE (ADDITION OF ZERK FITTINGS).ODI INTENDS TO OBTAIN AN UNDERSTANDING OF WHY THERE ARE SEEMINGLY SIGNIFICANT DIFFERENCES IN THE COMPLAINT DATA AND WARRANTY CLAIMS BEFORE AND AFTER THE MAY 2004 DESIGN CHANGE AND THE SAFETY CONSEQUENCES OF THE PRE-CHANGE DESIGN. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-016) FOR FURTHER INVESTIGATION.

SERVICE BRAKES, HYDRAULIC

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

ElectricalVisibility
Filed Jun 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

NHTSA ID
10275057
Incident
May 1, 2009
Brakes
Filed Oct 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

NHTSA ID
10247194
Incident
Oct 13, 2008
Mileage
38,133 mi
BrakesOther / unspecified
Filed Sep 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 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

NHTSA ID
10243450
Incident
Sep 7, 2007
Mileage
10,920 mi
Brakes
Filed Feb 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

NHTSA ID
10217086
Incident
Jan 28, 2008
Mileage
30,000 mi
Brakes
Filed Feb 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

NHTSA ID
10216819
Incident
Jan 18, 2008
Mileage
17,600 mi
Brakes
Filed Sep 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 SERVICE CENTER AND THE COAST CAN BE PROVIDED UPON REQUEST

NHTSA ID
10202938
Incident
Aug 20, 2007
Mileage
20,100 mi
Brakes
Filed Sep 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

NHTSA ID
10201868
Incident
Sep 19, 2006
Mileage
10,506 mi

Compare model years

Complaint and recall counts across every year of this model

Workhorse W20 by model year
YearComplaintsRecallsInvestigationsIssue Index
2008010—
2007010—
2006320—
2005322—
2004Viewing722—
2003111235.8
2002623—
2001233—
2000112—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.