VehicleVerdict

2004 Workhorse W22 problems

Verdict · NHTSA data

One of the years to avoid

With 107 complaints filed to NHTSA — about 13.4 times the median W22 year — the 2004 model ranks #2 of 11 W22 years for complaint volume. It lands on the years-to-avoid list.

The trouble concentrates in one system: brakes issues account for 81% of all reports (87 of 107), far ahead of engine at 4.

107

NHTSA complaints

2

Recalls

1

Investigations

0

Crash-involved

3

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other W22 years?

W22 NHTSA complaints by model year, 2004 highlighted130 complaints2000: 1 complaints2001: 14 complaints2002: 76 complaints2003: 130 complaints2004: 107 complaints2005: 22 complaints2006: 8 complaints2007: 6 complaints2008: 4 complaints2009: 2 complaints2011: 0 complaints
W22 NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all W22 years to avoid →

What are the most common 2004 Workhorse W22 problems?

ComponentComplaintsShare
Brakes8781%
Electrical System44%
Engine44%
Other33%
Fuel System33%
Transmission22%
Lighting11%
Seat Belts11%
Body & Structure11%
Suspension11%

Does the 2004 Workhorse W22 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.

“TL*THE CONTACT OWNS A 2004 GULF STREAM SUN VOYAGER RV. THE VEHICLE HAS A WORKHORSE W22 CHASSIS. IN JULY OF 2008, THE FRONT DRIVER'S SIDE CALIPER CAUGHT FIRE. THE CALIPER WAS REPLACED. ON MAY 22, 2009, THE CONTACT FELT THE VEHICLE PULLING TO ONE SIDE WHILE DRIVING 65 MPH. SHE PULLED THE VEHICLE OVER…”

Complaint filed with NHTSA · Brakes · July 1, 2008 · fire

“BOTH OF MY CATALYTIC CONVERTERS FAILED 2/16/11 ON MY 2004 W22 WORKHORSE CHASSIS WITH ONLY 30,000 MILES. REPLACEMENT COST $1,200.00. THERE WAS A RECALL REPLACING DEFECTIVE CATALYTIC CONVERTERS ON THE 2003 WORKHORSE CHASSIS. IS THIS THE CONTINUATION OF THE SAME PROBLEM OF DEFECTIVE CATALYTIC…”

Complaint filed with NHTSA · Engine · February 16, 2011

“I HAVE A HOLIDAY RAMBLER VACATIONER MOTOR HOME WITH A WORKHORSE CHASSIS THERE IS A RECALL NHTSA # 06V22700 FOR AN INSTRUMENT CLUSTER PANEL, WHICH WAS REPLACED ON MY VEHICLE, THAT CONTINUES TO BLANK OUT INTERMINTANTLY CAUSING THE PANEL TO GO DARK AT NIGHT, BUZZING ALARM, AND ALL THE GUAGES TO RESET.…”

Complaint filed with NHTSA · Electrical System · May 12, 2004

“TL- THE CONTACT OWNS A 2004 WINNEBAGO. THE CONTACT NOTICED THAT HIS NORCOLD REFRIGERATOR'S COOLING FLUID WAS LEAKING. THE REFRIGERATOR WAS INSPECTED BY THE CONTACTS PERSONAL MECHANIC WHO STATED THAT THE HIGH TEMPERATURE CENSOR NEEDED TO BE REPAIRED. THE REFRIGERATOR HAD BEEN REPAIRED; HOWEVER THE…”

Complaint filed with NHTSA · Other · September 15, 2010

“FRONT ENGINE GASOLINE POWERED MOTORHOME WAS IN SERVICE SHOP FOR LEAKING REAR AXLE HUB. AFTER THAT WAS FIXED, SHOP OWNER WAS MOVING UNIT WHEN SIGNIFICANT FUEL WAS OBSERVED LEAKING FROM ENGINE AREA (FRONT OF UNIT) ONTO THE GROUND. FUEL ALSO SOAKED THE CARPET NEAR THE DRIVER AND DRIVER'S FOOT BECAME…”

Complaint filed with NHTSA · Fuel System · April 25, 2006

2004 Workhorse W22 — common questions

Is the 2004 Workhorse W22 reliable?

NHTSA data argues against it: 107 complaints put the 2004 model at #2 of 11 W22 years. It is one of the W22 years to avoid.

What are the most common 2004 W22 problems?

According to NHTSA complaint data, the leading problem areas are brakes (87 complaints), engine (4 complaints), electrical system (4 complaints).

Does the 2004 Workhorse W22 have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Workhorse W22. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Workhorse W22 under NHTSA investigation?

NHTSA opened one investigation into this model year; all are now closed.

Which Workhorse W22 years should you avoid?

Based on complaint rates and open investigations, the W22 years to avoid are 2003, 2004, 2002. The cleanest record among W22 years belongs to 2011.

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.