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NHTSA vehicle safety data

2004 Workhorse W20 Recalls & Complaints

The 2004 Workhorse W20 has 2 NHTSA recall campaigns and 7 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Workhorse dealer.

NHTSA recall and complaint data for the 2004 Workhorse W20. Recall data is refreshed daily from NHTSA.

2004 Workhorse W20 owner complaints

Owners have filed 7 complaints with NHTSA about the 2004 Workhorse W20, describing incidents dated September 19, 2006 to May 1, 2009.

Most-cited components

  • Service Brakes 6 complaints
  • Electrical System 1 complaint
  • Visibility/Wiper 1 complaint
  • Wheels 1 complaint

Newest complaints

  • ODI #10275057 · Filed

    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…

  • ODI #10247194 · Filed

    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…

  • ODI #10243450 · Filed

    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…

Read all 7 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Workhorse W20 in 2 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Open and recently closed NHTSA defect investigations

OVERHEATED BRAKE CALIPERS/BOSCH/WORKHORSE

NHTSA #09V110000 · Service Brakes, Hydraulic · NHTSA notice

Reported April 3, 2009 · NAVISTAR, INC

Potentially affected: 48,876 vehicles

Manufacturer campaign 50901-C & 51101-C · Owners notified September 16, 2010 · Vehicles built July 24, 2000 – December 19, 2007 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

WORKHORSE RECALL NO. 50901-C AND 51101-C.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

FUEL RAIL DAMPER RETAINER CLIP

NHTSA #06V225000 · Engine and Engine Cooling · NHTSA notice

Reported June 20, 2006 · WORKHORSE CUSTOM CHASSIS

Potentially affected: 30,335 vehicles

Workhorse campaign 60601-C · Owners notified September 1, 2006 · Vehicles built May 13, 2003 – June 29, 2006 (per NHTSA)

Defect description

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.

Safety consequence

IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD RESULT.

Manufacturer 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.

Notes

WORKHORSE RECALL NO. 60601C.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Other Workhorse W20 model years

Check your 2004 Workhorse W20 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Workhorse W20 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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