VehicleVerdict

2004 Workhorse W20 problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 11 complaints on file for the 2004 Workhorse W20 — too few to judge reliability from owner reports alone — but 2 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

11

NHTSA complaints

2

Recalls

2

Investigations

0

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other W20 years?

W20 NHTSA complaints by model year, 2004 highlighted12 complaints2000: 1 complaints2001: 2 complaints2002: 6 complaints2003: 12 complaints2004: 11 complaints2005: 3 complaints2006: 3 complaints2007: 0 complaints2008: 0 complaints
W20 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all W20 years to avoid →

What are the most common 2004 Workhorse W20 problems?

ComponentComplaintsShare
Brakes873%
Electrical System19%
Tires & Wheels19%
Visibility & Wipers19%

Does the 2004 Workhorse W20 have recalls?

2 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

09V110000BrakesApril 3, 2009 · 48,876 units

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. 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.

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.

06V225000EngineJune 20, 2006 · 30,335 units

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“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…”

Complaint filed with NHTSA · Brakes · September 19, 2006

“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…”

Complaint filed with NHTSA · Visibility & Wipers · May 1, 2009

“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…”

Complaint filed with NHTSA · Electrical System · May 1, 2009

2004 Workhorse W20 — common questions

Is the 2004 Workhorse W20 reliable?

The record is thin — 11 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 2 recalls should be verified as completed.

What are the most common 2004 W20 problems?

According to NHTSA complaint data, the leading problem areas are brakes (8 complaints), tires & wheels (1 complaints), visibility & wipers (1 complaints).

Does the 2004 Workhorse W20 have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Workhorse W20. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Workhorse W20 under NHTSA investigation?

NHTSA opened 2 investigations into this model year; all are now closed.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.