2004 WORKHORSE W20 — Problems, Recalls & Safety Data
N/A
Safety Rating
11
Owner Complaints
2
Recalls
0
Service Bulletins
1
Investigation
Overview of the 2004 WORKHORSE W20
The 2004 WORKHORSE W20 has received a total of 11 safety complaints filed with the National Highway Traffic Safety Administration (NHTSA). There have been 2 recall campaigns affecting this vehicle, covering issues with SERVICE BRAKES, HYDRAULIC, ENGINE AND ENGINE COOLING. The most commonly reported problems involve the Service Brakes Hydraulic (3 complaints), Electrical System Instrument Clusterpanel (1 complaint), and Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slip (1 complaint).
Recalls for the 2004 WORKHORSE W20
NHTSA has recorded 2 recalls for the 2004 WORKHORSE W20, potentially affecting up to 79,211 vehicles.
Recall 09V110000 — SERVICE BRAKES, HYDRAULIC
| 48,876 vehicles affected
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....
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.
View full details →Recall 06V225000 — ENGINE AND ENGINE COOLING
| 30,335 vehicles affected
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.
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.
View full details →Owner Complaints for the 2004 WORKHORSE W20
11 complaints have been filed with NHTSA for the 2004 WORKHORSE W20. Below is a breakdown by vehicle component.
| Component | Complaints | Crashes | Fires | Injuries | Deaths |
|---|---|---|---|---|---|
| Service Brakes Hydraulic | 3 | 0 | 0 | 0 | 0 |
| Electrical System Instrument Clusterpanel | 1 | 0 | 0 | 0 | 0 |
| Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slip | 1 | 0 | 0 | 0 | 0 |
| Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slipabs Warning Light | 1 | 0 | 0 | 0 | 0 |
| Service Brakes Hydraulicfoundation Componentsdisccaliper | 1 | 0 | 0 | 0 | 0 |
| Service Brakes Hydraulicfoundation Componentsdiscrotor | 1 | 0 | 0 | 0 | 0 |
| Service Brakes Hydraulicfoundation Componentsdrumwheel Cylinders | 1 | 0 | 0 | 0 | 0 |
| Visibility | 1 | 0 | 0 | 0 | 0 |
| Wheels | 1 | 0 | 0 | 0 | 0 |
Most Recent Complaints
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
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 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
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
Safety Rating for the 2004 WORKHORSE W20
NHTSA has not yet tested the 2004 WORKHORSE W20 in its New Car Assessment Program.
Technical Service Bulletins for the 2004 WORKHORSE W20
No technical service bulletins have been reported for this vehicle.
NHTSA Investigations for the 2004 WORKHORSE W20
NHTSA has opened 1 investigation into potential safety defects in the 2004 WORKHORSE W20.
Other Model Years of the WORKHORSE W20
- 2000 WORKHORSE W20 — 1 complaint
- 2001 WORKHORSE W20 — 2 complaints
- 2002 WORKHORSE W20 — 6 complaints
- 2003 WORKHORSE W20 — 12 complaints
- 2004 WORKHORSE W20 (current)
- 2005 WORKHORSE W20 — 3 complaints
- 2006 WORKHORSE W20 — 3 complaints
- 2007 WORKHORSE W20 — 0 complaints
- 2008 WORKHORSE W20 — 0 complaints
Other WORKHORSE Models
- WORKHORSE W22 — 370 total complaints
- WORKHORSE CHASSIS — 72 total complaints
- WORKHORSE P320032 — 32 total complaints
- WORKHORSE P30 — 9 total complaints
- WORKHORSE P32 — 4 total complaints
- WORKHORSE W18 — 4 total complaints
- WORKHORSE W24 — 4 total complaints
- WORKHORSE P3500 — 3 total complaints