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2004 Workhorse Chassis

Owner reports · Recalls · Investigations

Limited comparison data

There is not enough comparable history to draw a useful model-year comparison.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

28 reports with mileage · 6 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 26 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 2 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports2 fire reports0 injury reports

Service Brakes, Hydraulic complaints

26 reports
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13,728 miles · Dec 28, 2008
Service Brakes, Hydraulic

WORKHORSE W22 WITH BRAKE CALIPER PROBLEMS. HAVE CHANGED 5 CALIPERS, 3 SEALS AND TWO ROTORS ON A 3 YEAR OLD MOTORHOME WITH 17,000 ON IT. *TR

NHTSA ODI #10252984

22,300 miles · Oct 30, 2008
Service Brakes, HydraulicTires

TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE HAD A PREMATURE TIRE BLOW OUT. THE CONTACT PULLED OVER TO THE SIDE OF THE ROAD AND THE VEHICLE WAS TOWED TO A LOCAL TIRE SHOP. THE TIRE WAS REPLACED AND THE CONTACT DROVE TO HIS RESIDENCE. APPROXIMATELY ONE WEEK LATER, HE DROVE TO A…

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TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE HAD A PREMATURE TIRE BLOW OUT. THE CONTACT PULLED OVER TO THE SIDE OF THE ROAD AND THE VEHICLE WAS TOWED TO A LOCAL TIRE SHOP. THE TIRE WAS REPLACED AND THE CONTACT DROVE TO HIS RESIDENCE. APPROXIMATELY ONE WEEK LATER, HE DROVE TO A LOCAL TIRE SHOP TO HAVE THE FIVE REMAINING TIRES REPLACED AND WAS INFORMED THAT THE BRAKE ROTORS WERE CRACKED ON THE FRONT DRIVER'S SIDE. THE MECHANIC DID NOT EXPLAIN HOW THE FAILURE OCCURRED. THE VEHICLE HAS NOT BEEN REPAIRED. THE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS 24,939 AND FAILURE MILEAGE WAS 22,300.

NHTSA ODI #10247258

8,500 miles · Oct 21, 2008
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING APPROXIMATELY 20 MPH, THE CONTACT NOTICED A SMELL COMING FROM THE VEHICLE. IN ADDITION, THE BRAKES BEGAN LOCKING. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND HE NOTICED THAT THE REAR PASSENGER SIDE BRAKES WERE HOT. THE FAILURE HAS RECURRED REPEATEDLY EVE…

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TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING APPROXIMATELY 20 MPH, THE CONTACT NOTICED A SMELL COMING FROM THE VEHICLE. IN ADDITION, THE BRAKES BEGAN LOCKING. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND HE NOTICED THAT THE REAR PASSENGER SIDE BRAKES WERE HOT. THE FAILURE HAS RECURRED REPEATEDLY EVER SINCE. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT BEING REPAIRED AND THEY WERE NOT LIABLE FOR THE REPAIRS. THERE HAS BEEN NO DEFINITIVE DIAGNOSIS. THE DEALER HAS NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS 9,980 AND FAILURE MILEAGE WAS 8,500.

NHTSA ODI #10246247

13,761 miles · Mar 25, 2008
Service Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING 55 MPH, THE CONTACT SMELLED AN ODOR. HE STOPPED AND INSPECTED THE VEHICLE, BUT FOUND NO FAILURE. AS HE CONTINUED DRIVING, THE ODOR INTENSIFIED. THE CHASSIS WAS TOWED TO THE DEALER AND THEY STATED THAT THE DRIVER'S SIDE BRAKE LOCKED AND CAUSED IT TO STICK TO THE ROTO…

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TL*THE CONTACT OWNS A 2004 WORKHORSE CHASSIS. WHILE DRIVING 55 MPH, THE CONTACT SMELLED AN ODOR. HE STOPPED AND INSPECTED THE VEHICLE, BUT FOUND NO FAILURE. AS HE CONTINUED DRIVING, THE ODOR INTENSIFIED. THE CHASSIS WAS TOWED TO THE DEALER AND THEY STATED THAT THE DRIVER'S SIDE BRAKE LOCKED AND CAUSED IT TO STICK TO THE ROTOR. THE FAILURE THEN CAUSED THE ROTOR TO OVERHEAT. THE DEALER REPLACED THE ROTOR, BRAKES, CALIPER, AND DISC PAD SEAL HOSE. THE MANUFACTURER STATED THAT NO RECALLS WERE AVAILABLE. THE CURRENT MILEAGE IS 13,880 AND FAILURE MILEAGE WAS 13,761 UPDATED 04-08-08 *BF THE FRONT CALIPER SEIZED WHICH CREATED EXCESSIVE FRICTION ON THE ROTOR WHICH RESULTED IN THE ROTOR BECOMING WARPED. UPDATED

NHTSA ODI #10222296

17,000 miles · Sep 12, 2007
Service Brakes, Hydraulic

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. U…

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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

NHTSA ODI #10202766

Mileage unknown · Oct 5, 2005
Service Brakes, Hydraulic

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…

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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 THE MOTORHOME OFF THE ROAD. THE LACK OF POWER THE CONSUMER EXPERIENCED WAS DUE TO THE BRAKES NOT RELEASING. THE CONSUMER CALLED A TOW TRUCK, WHEN THE TOW TRUCK DRIVER DISCONNECTED THE DRIVESHAFT HE DISCOVERED WHY THE ABS LIGHT HAD COME, THE SENSOR AND WIRE WERE COMPLETELY MELTED. THE MECHANIC FIXED THE RESULT OF THE MALFUNCTION, BUT NOT THE MALFUNCTION. AFTER GETTING THE RV BACK,THE CONSUMER FELT A LOSS OF POWER AND COULD SEE A DROP IN GAS MILEAGE. THE CONSUMER HEARD A NOISE, BUT WHEN HE TAPPED THE BRAKES THE NOISE WENT AWAY. THE CONSUMER BELIEVED THE PROBLEM WAS EITHER THE BOOSTER PUMP OR BOOSTER PUMP SWITCH STICKING WHICH WAS PREVENTING THE BRAKES FROM RELEASING ALL THE WAY. *JB

NHTSA ODI #10138878

Official recalls

1

04V195000 · Electrical System

Apr 22, 2004

CERTAIN CHASSIS EQUIPPED WITH ACTIA CORPORATE INSTRUMENT CLUSTERS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS. 101 "CONTROLS AND DISPLAYS" AND 105 "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." IF THE BRAKE FAIL INPUT FALLS BELOW A VOLTAGE OF 1.5V, THE BRAKE FAILURE LAMP AND ALARM WILL BE ACTIVATED. ALSO ACTIVATION OF THE ABS TELL TALE WHEN THE ABS IS NOT PROPERLY FUNCTIONING DOES NOT ALWAYS OCCUR.

Consequence & remedy

Consequence: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Remedy: WORKHORSE WILL NOTIFY ITS CUSTOMERS AND REPROGRAM THE INSTRUMENT PANEL CLUSTER FREE OF CHARGE. THE RECALL BEGAN JANUARY 2005. OWNERS SHOULD CONTACT WORKHORSE AT 1-877-246-7731.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.