IllustrationREAR BRAKE CALIBERS FAILING AND REPLACING AT 16,000 MILES AND THE FRONT DOING THE SAME AT 26,500 MILES...INFORMATION BELOW IS FOR THE RECENT FAILURE, THE REAR FAILED IN 2007. *TR
2004 Workhorse W22
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all W22 years →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
450–25K
1825–50K
150–75K
075–100K
0100–150K
0150K+
64 reports with mileage · 28 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 74 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 4 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 reports3 fire reports0 injury reports
Service Brakes, Hydraulic complaints
74 reportsCOMPLETE BRAKE FAILURE AT 55 MPH DUE TO REAR BRAKE BEING LOCKED UP AND OVERHEATING. MECHANIC SAID IT WAS DEFECTIVE CALIPERS. *JB
ON 9 MAR 2006 I WAS TRAVELING ON LA HIGHWAY 128 ENROUTE TO WINNSBORO, LA IN MY 24' 2004 WINNEBAGO MOTORHOME BUILT ON A WORKHORSE CHASSIS. TIME OF DAY WAS AROUND 7:30 AM, ROAD WAS DRY AND FLAT. TEMPERATURE WAS PROBABLY IN HIGH 60'S (DEG F) TO LOW 70'S. I HAD ENGAGED CRUISE CONTROL AT 50 MPH AND OVERDRIVE WAS ENGAGED. WITHOUT…
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ON 9 MAR 2006 I WAS TRAVELING ON LA HIGHWAY 128 ENROUTE TO WINNSBORO, LA IN MY 24' 2004 WINNEBAGO MOTORHOME BUILT ON A WORKHORSE CHASSIS. TIME OF DAY WAS AROUND 7:30 AM, ROAD WAS DRY AND FLAT. TEMPERATURE WAS PROBABLY IN HIGH 60'S (DEG F) TO LOW 70'S. I HAD ENGAGED CRUISE CONTROL AT 50 MPH AND OVERDRIVE WAS ENGAGED. WITHOUT WARNING THE STEERING COLUMN BEGAN TO VIOLENTLY SHAKE, THE ALLISON 1000 TRANSMISSION SLIPPED OUT OF OD INTO 3D GEAR AND THEN IMMEDIATELY SHIFTED INTO 2D GEAR. CRUISE CONTROL REMAINED ENGAGED. ENGINE SPEED REMAINED AT ABOUT 1500-1800 RPM BUT ROAD SPEED DROPPED TO NEARLY 0 MPH. AFTER SHUTTING THE ENGINE DOWN I SMELLED AN ODOR OF HOT METAL. I INSPECTED THE COACH INSIDE AND OUTSIDE BUT DID NOT FIND ANY VISIBLE SMOKE OR FLAME. I RETURNED TO THE COACH, RESTARTED THE ENGINE, AND PROCEEDED WITHOUT FURTHER DIFFICULTY. DURING THE ABOVE DESCRIBED ACTION THE COACH DID NOT PULL EITHER RIGHT OR LEFT, AND THERE WERE NO ALARMS, EITHER VISUAL OR AURALLY FROM THE DISPLAY LANEL. THIS LEADS ME TO BELIEVE THAT THE FRONT LEFT AND RIGHT DISK BRAKES CLOSED ON THE ROTORS EQUALLY, CAUSING THE COACH TO COME TO A STRAIGHT-LINE STOP. I HAVE READ OF PREVIOUS MODELS (2002 AND PERHAPS 2003) OF THIS SAME CHASSIS EQUIPPED WITH BOSCH CALIPERS HAVING BRAKE PROBLEMS RESULTING IN FIRES AND OTHER SERIOUS DAMAGE TO THE VEHICLE. I NOW BELIEVE THAT THIS PROBLEM IS SURFACING ONCE AGAIN, THIS TIME IN THE 2004 WORKHORSE CHASSIS. A CALL TO THE MANUFACTURER RESULTED IN NO OFFER OF A POSSIBLE CAUSE, OR OTHER ADVICE.*JB
2004 WORKHORSE W22. AFTER TURNING OFF THE IGNITION A WHIRRING SOUND BEGAN. THE CONSUMER SOON LEARNED THAT WHEN PRESSING THE BRAKE PEDAL TO START THE VEHICLE, THERE WAS NO WHIRRING SOUND. *PH THE CONSUMER OPEN THE HOOD AND DETERMINED THAT THE NOISE WAS COMING FROM THE BRAKE BOX. THE CONSUMER STATED THE BRAKES WOULD SQUEAK WH…
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2004 WORKHORSE W22. AFTER TURNING OFF THE IGNITION A WHIRRING SOUND BEGAN. THE CONSUMER SOON LEARNED THAT WHEN PRESSING THE BRAKE PEDAL TO START THE VEHICLE, THERE WAS NO WHIRRING SOUND. *PH THE CONSUMER OPEN THE HOOD AND DETERMINED THAT THE NOISE WAS COMING FROM THE BRAKE BOX. THE CONSUMER STATED THE BRAKES WOULD SQUEAK WHEN APPLIED AND ALSO LOCK UP. ALSO, THE BRAKE WARNING LIGHT WOULD ILLUMINATE. A RECALL WAS FINALLY ISSUED. THE RV WAS AT THE DEALER FOR 31 DAYS BECAUSE THE BRAKE PARTS WERE NOT AVAILABLE. THE CALIPERS WERE FINALLY REPLACED ALONG WITH A BROKEN ROTOR ON THE LEFT SIDE OF THE RV. THE CONSUMER WAS ADVISED THAT WORKHORSE WOULD NOT COVER THE BROKEN THE ROTOR AS A WARRANTY ITEM AND THE CONSUMER WOULD BE RESPONSIBLE FOR THE PART AND LABOR. UPDATED 12/23/10
Official recalls
209V110000 · Service Brakes, Hydraulic
Apr 3, 2009
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.
Consequence & remedy
Consequence: 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.
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.
06V225000 · Engine And Engine Cooling
Jun 20, 2006
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.
Consequence & remedy
Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.
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.
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
1EA07016 · Overheating Disc Brake Caliper
Opened Nov 16, 2007 · Closed Aug 19, 2009
Status: closed (inferred from source dates) · Service Brakes, Hydraulic
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.
Additional source detail variants (7)
Service Brakes, Hydraulic
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, Hydraulic
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, Hydraulic
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, Hydraulic
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, Hydraulic
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, Hydraulic
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, Hydraulic
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.