Total Complaints
11 filings
WORKHORSE W20 · model year
2004 WORKHORSE W20
11 NHTSA complaints, and 2 active recalls for this specific cohort.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
The 2004WORKHORSEW20 carries 11 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 0 crashes, 0 fires, 0 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 W20 is service brakes, hydraulic with 3 filings, followed by service brakes, hydraulic:foundation components:disc:caliper (1) and service brakes, hydraulic:foundation components:disc:rotor (1). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 2 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle — the full NHTSA campaign numbers are listed below.
NHTSA currently has 2 investigation files overlapping the 2004 W20. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.
11
Complaints
0
Crashes
0
Fires
0
Injuries
0
Deaths
Crashes Reported
0 reports
Source
NHTSA ODI
Federal complaints database
Complaints vs. fleet median (215)
At or below the fleet median complaint volume.
Complaints by Component
| Component | Count |
|---|---|
| SERVICE BRAKES, HYDRAULIC | 3 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER | 1 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR | 1 |
| SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:WHEEL CYLINDERS | 1 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP | 1 |
| SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT | 1 |
| WHEELS | 1 |
| ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL | 1 |
| VISIBILITY | 1 |
Recalls (2)
06V22500020/06/2006
ENGINE AND ENGINE COOLING
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 PUMP
09V11000003/04/2009
SERVICE BRAKES, HYDRAULIC
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 W
Recent Complaints
20090626ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
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
20090626VISIBILITY
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
20081029SERVICE BRAKES, HYDRAULIC
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
Mileage: 38,133
20080925SERVICE BRAKES, HYDRAULIC
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
Mileage: 10,920
20080925WHEELS
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
Mileage: 10,920
20080206SERVICE BRAKES, HYDRAULIC
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
Mileage: 30,000
20080203SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP
RIGHT FRONT DISC BRAKE OVERHEATED AND CAUSED OIL SEAL FAILURE RESULTING IN CONTAMINATION OF DISC BRAKE LINING CONTAMINATION AND REDUCED BRAKE EFFECTIVENESS. *TR
Mileage: 17,600
20080203SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT
RIGHT FRONT DISC BRAKE OVERHEATED AND CAUSED OIL SEAL FAILURE RESULTING IN CONTAMINATION OF DISC BRAKE LINING CONTAMINATION AND REDUCED BRAKE EFFECTIVENESS. *TR
Mileage: 17,600
20070913SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:WHEEL CYLINDERS
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
Mileage: 20,100
20070904SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER
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
Mileage: 10,506
20070904SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR
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
Mileage: 10,506
Compare 2004WORKHORSEW20 to Similar Vehicles
NHTSA Investigations
Frequently Asked Questions
How many complaints does the 2004 WORKHORSE W20 have?▼
The 2004 WORKHORSE W20 has 11 NHTSA complaints, 0 crashes, 0 fires, 0 injuries, and 0 deaths reported.
Are there any recalls for the 2004 WORKHORSE W20?▼
Yes, the 2004 WORKHORSE W20 has 2 recall(s). The most common affected component is ENGINE AND ENGINE COOLING. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 WORKHORSE W20?▼
The most-complained component for the 2004 WORKHORSE W20 is SERVICE BRAKES, HYDRAULIC with 3 complaints. Other frequently reported areas include SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER and SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:ROTOR.
Is the 2004 WORKHORSE W20 safe to buy?▼
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?▼
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.
Vehicle Safety Guides
Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Read our methodology — how this data is sourced, computed, and verified.