The contact owns a 2004 Workhorse W22. The contact stated that after the RV was stored for several years, the contact learned that the brakes had seized. The contact then became aware that the RV was included in a recall. The RV was taken to the dealer and repaired under the federal safety agency Campaign Number: 09V110000 (Service Brakes, Hydraulic) however, the RV experienced brake failure. The contact stated that after the repair due, to personal issues, he was unable to use the RV for several months. The contact stated that he recently started driving the RV around the property and locally; however, he became aware of brake fluid leaking underneath the RV. There was no warning light illuminated. The contact had not taken the RV to the dealer. The manufacturer was not made aware of the failure. The approximate failure mileage was 23,022.
The worst 2004 Workhorse W22 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Brakes83
- Electrical4
- Engine4
- Fuel system2
- Body1
- Lights1
- Seat belts1
- Suspension1
- Transmission1
Specific symptoms reported on the 2004 Workhorse W22
ABS 25Overheating 21Brake failure 20Fire or smoke 9Engine failure 5
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 W22
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
What 2004 Workhorse W22 owners say
Most recent owner complaints, unedited.
The contact owns a 2004 Workhorse W22 RV. The contact stated while driving approximately 60 MPH, the brakes heated up and seized. The contact stated that the ABS warning light was illuminated. The contact pulled over and smelled a burning odor. The contact stated that he waited for over one hour for the brakes to cool and then he continued driving to his destination. The contact stated that the failure became constant and he no longer took the RV on long trips. The contact had taken the RV to an independent mechanic where it was diagnosed and determined that the calipers, pistons, sensors, and rotors needed to be replaced. The RV had been repaired; however, the failure reoccurred. The manufacturer had not been informed of the failure. The failure mileage was approximately 60,000.
The contact owns a 2004 Newmar Kountry built on a 2004 Workhorse W22 chassis. The contact stated while driving 70 MPH, the brake pedal was depressed but failed to respond as needed. The contact was able to continue driving. The vehicle was taken to an independent mechanic on four occasions where the brake pads were replaced four times however, the failure persisted. The contact stated while driving on a wet road surface and attempting to make a stop at the stop sign, the vehicle slid into a ditch. The contact did not sustain any injuries. The contact was able to pull the RV out of the ditch with the assistance of a four-wheel drive vehicle. The contact’s friend, an independent mechanic, arrived at the scene and diagnosed that the brake calipers had seized, causing the brakes to overheat while driving. Additionally, the independent mechanic diagnosed that the brake rotors needed to be replaced. The mechanic performed an unknown service on the brakes which allowed the contact to drive to his residence. However, the failure reoccurred and the brake pedal was smoking. The contact became aware that the VIN was included in the federal safety agency Campaign Number: 09V110000 (Service Brakes, Hydraulic). The manufacturer was notified of the failure and referred the contact to the dealer for assistance. The dealer informed the contact that they needed to verify that the manufacturer would cover the recall repair prior to assisting. The contact contacted other unknown dealers who declined to assist. The vehicle was not repaired. The failure mileage was approximately 30,000.
2004 chevrolet gulf stream. Consumer writes in regards to brake system recall repair issues - right front caliper/ABS sensor replacements. *smd
2000 miles after recall was fixed when brakes applied steering wheel pulls your hands off and goes to the right and cant keep it in the road.
Tl* the contact owns a 2004 workhorse w22 chassis motorhome. The contact stated that while traveling approximately 15 MPH, the brakes failed and the pedal sank to the floor. The contact had to apply the emergency brake in order to stop the vehicle. The authorized dealer was not able to provide a remedy. The vehicle was not repaired. The contact was not notified or included in recall the federal safety agency campaign id number: 09v110000 (service brakes, hydraulic). The manufacturer was notified of the failure. The approximate failure mileage was 19,870.
Tl* the contact owns a 2004 fleet wood motor home equipped with a workhorse w22 chassis. The contact stated that while driving 45 MPH, the vehicle started to decelerate. After inspecting the vehicle, he noticed that the rear brakes were on fire. The contact was able to contain the fire by using an extinguisher. The vehicle was towed to the dealer where the technician verified that the brakes failed and the brakes, rotor, brake caliper, speed sensor and the brake lines would need replacing. The manufacturer was made aware of the failure. The vehicle was not repaired. The failure and current mileage was 23,000.
Tl* the contact owns a 2004 georgi boy cruse master rv equipped with a 2004 workhorse w22 chassis. The contact was driving approximately 55 MPH when the brake pedal was engaged and the vehicle failed to decelerate. The contact was able to reduce speed after applying the brakes repeatedly and to a complete stop. After thirty minutes the vehicle resumed normally. The vehicle was previously repaired under a the federal safety agency campaign id number: 09v193000 (service brakes, hydraulic). The failure recently recurred and the vehicle was not repaired. The manufacturer was notified of the problem. The approximate failure mileage was 12,000...updated 05/16/13 *bf the consumer stated the breaks and rotors should have been changed. They were warped from the excessive heat caused by calipers hanging up. Updated 05/23/2013
2004 georgie boy cruise master class a motor home on a 2004 workhorse chassis. Consumer writes in regards to problem with brakes *tgw the consumer stated the problem first began in september 2007, when the brakes began overheating and smoking. The consumer had the rv towed . Workhorse paid part of the bill because the rv was still under warranty. In august 2009, the brakes failed and the rv would not stop. The rv was towed again, where the braking system was repaired. In september 2010, the consumer received a recall letter from workhorse regarding a problem with the brakes. The consumer took the rv to a repair facility to have it inspected. The rv failed inspection, due to the braking system overheating and smoking. The consumer contacted workhorse while at the repair facility and workhorse refused to absorb the cost of having the rv towed to an authorized service center. The consumer informed workhorse, the brakes were overheating and smoking and he would not be able to drive it. A representative from the repair shop informed workhorse it was their responsibility to have the rv towed. Workhorse decided to pay for the towing. Repairs were only made to the calipers. In july 2011, the rv would not stop and went out of control on the interstate, forcing the consumer off the highway. The consumer contacted workhorse again, to inform them of the brake failure and they refused to have the rv towed or pay for any of the repairs.
2005 damon challenger rv on a 2004 w22 workhorse chassis. Consumer states the hydraulic brake line is in contact with the exhaust system on both sides of the unit (rear axle)
Compare the 2004 Workhorse W22
Other model years
Questions about the 2004 Workhorse W22
Is the 2004 Workhorse W22 reliable?
Owners have filed 92 complaints about the 2004 Workhorse W22, 9.2 times a typical W22 model year. It is one of the years we flag to avoid.
What is the 2004 Workhorse W22 year score?
The 2004 Workhorse W22 scores 5 out of 100 (poor). The score compares it with the other model years of the Workhorse W22: 75 is a typical year, 50 means twice the usual complaints, and serious complaints and recalls lower it.
What is the most common problem with the 2004 Workhorse W22?
Brakes, with 83 complaints, typically around 21,960 miles. Next is electrical (4).
How many recalls does the 2004 Workhorse W22 have?
2 recalls, covering service brakes, hydraulic and engine and engine cooling.
Was there a recall on the 2004 Workhorse W22 brakes?
Yes, 1 recall: 09V110000. Check your VIN to see if your car still needs the free repair.
What year does the Workhorse W22 have bad brakes?
The Workhorse W22 model years with the most brakes complaints are 2003 (111 complaints), 2004 (83 complaints) and 2002 (64 complaints).
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