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.
The worst 2004 Workhorse W20 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
- Brakes6
- Electrical1
- Visibility1
- Wheels1
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Brakes6
- Electrical1
- Visibility1
- Wheels1
Recalls 2
Service brakes, hydraulic
- What is wrong
- 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.
- 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.
- 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.
Recall number 09V110000 · Recall details
Engine and engine cooling
- What is wrong
- 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.
- Risk
- 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.
Recall number 06V225000 · Recall details
See all 2 recalls for the 2004 Workhorse W20
Defect investigations
Overheating disc brake caliper
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.
EA07016
Overheated brake calipers
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.
PE07032
What 2004 Workhorse W20 owners say
Most recent owner complaints, unedited.
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.
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!
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 the federal safety agency action number: ea07016.
Right front disc brake overheated and caused oil seal failure resulting in contamination of disc brake lining contamination and reduced brake effectiveness.
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
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
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Questions about the 2004 Workhorse W20
Is the 2004 Workhorse W20 reliable?
Owners have filed 7 complaints about the 2004 Workhorse W20, 1.2 times a typical W20 model year.
What is the most common problem with the 2004 Workhorse W20?
Brakes, with 6 complaints, typically around 17,600 miles. Next is electrical (1).
How many recalls does the 2004 Workhorse W20 have?
2 recalls, covering service brakes, hydraulic and engine and engine cooling.
Was there a recall on the 2004 Workhorse W20 brakes?
Yes, 1 recall: 09V110000. Check your VIN to see if your car still needs the free repair.
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