2004 Workhorse W22
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Workhorse › W22 › 2004
These records cover every 2004 Workhorse W22. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
2 recalls name the 2004 Workhorse W22. Newest first.
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…
Risk and remedy
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.
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 and remedy
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.
Owner complaints
92 complaints3 involved a fire
What owners report most
Latest complaints
- Service brakes, hydraulic
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 NHTSA Campaign Number…
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 NHTSA 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.
- Service brakes · Service brakes, air › Disc › Caliper
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…
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.
- Service brakes, hydraulic
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 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 NHTSA 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.
- Service brakes · Service brakes, hydraulic › Antilock/traction control/electronic limited slip › Wheel speed sensor/tone ring
2004 chevrolet gulf stream. consumer writes in regards to brake system recall repair issues - right front caliper/abs sensor replacements. *smd *tr
- Service brakes
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.
- Service brakes
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…
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 nhtsa campaign ID number: 09v110000 (service brakes, hydraulic). The manufacturer was notified of the failure. The approximate failure mileage was 19,870.
- Service brakes
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…
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.
- Service brakes · Service brakes, air › Disc › Caliper
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…
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 nhtsa 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 *js
- Service brakes, hydraulic
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…
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. *Jb
- Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittings
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) *tgw
- Fuel system, gasoline · Fuel system, gasoline › Storage › Tank assembly
Leaking gas tank as per nhtsa recall 10v348000. *tr
- Engine and engine cooling › Exhaust system
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 converters? I've kept my 8.1L tuned and serviced as per manufacture instructions. *tr
- Service brakes, hydraulic
Consumer states that his 2004 damon intruder on a 2004 W22 workhorse custom chassis experienced the caliper defects resulting in safety recall 50901-c. Consumer requests reimbursement for replacement calipers. *Tgw the consumer stated the brakes overheated to the point that a severe wobble had…
Consumer states that his 2004 damon intruder on a 2004 W22 workhorse custom chassis experienced the caliper defects resulting in safety recall 50901-c. Consumer requests reimbursement for replacement calipers. *Tgw the consumer stated the brakes overheated to the point that a severe wobble had developed in the front wheels and was causing the steering wheel to oscillate. The consumer stated the repairs cost $ 3,089.49 of which $1,751.10 was reimbursed by workhorse. The consumer IS requesting the remaining of the repair bill. *Jb
- Service brakes, hydraulic
Tl*the contact owns a 2004 fleetwood bounder. The contact stated that the when the brakes were engaged they would surge. The vehicle was taken to a local mechanic who stated that the rear rotors needed to be serviced again. The manufacturer was contacted and they were not willing to offer any…
Tl*the contact owns a 2004 fleetwood bounder. The contact stated that the when the brakes were engaged they would surge. The vehicle was taken to a local mechanic who stated that the rear rotors needed to be serviced again. The manufacturer was contacted and they were not willing to offer any assistance because the vehicle was not under warranty. The vehicle was repaired. The failure mileage was 696 and the current mileage was 35,000. updated 3/7/11 *cn updated 03/14/11
- Service brakes, hydraulic
2004 southwind motorhome on a 2004 workhorse W22 chassis. Consumer states that it IS involved in the workhorse recall for defect with bosch brakes. He states that he had to get a complete brake job. Consumer would like reimbursement for repairs. *kb all four rotors were cracked and had to be replaced. The consumer was denied reimbursement based on the brake problem being caused by fatigue. *jb
- Electrical system · Exterior lighting · Unknown or other
The above vehicle was purchased on 10/29/2010, while conducting the first 30 day riving test, it was noticed that the instrument cluster was not functioning properly, the display light will not come on and therefore had to drive in the evening without this knowledge. During the dailight, when I…
The above vehicle was purchased on 10/29/2010, while conducting the first 30 day riving test, it was noticed that the instrument cluster was not functioning properly, the display light will not come on and therefore had to drive in the evening without this knowledge. During the dailight, when I placed the vehicle in cruise control the instrument cluster failed to tell me so. There are many other features to this instument that I do not know if they work or not. Upon bringing the vehicle back to the purchasing dealer, I was told that the instrument panel had been previously recalled by the manufacturer and that the work had already been completed on april 2010 and therefore if I wanted it fixed, I would have to pay approximately $600.00 to get it fixed. This vehicle was sold to me while being unsafe to drive, how can they tell me that I would have to pay for a safety repair of this magnitude when it did not happen while I owned the vehicle. The workhorse recall number was bulletin no. 50402-C. It IS my contention that the dealership should pay for this very important part of the safety of this vehicle.
- Service brakes, hydraulic
2004 dolphin motor home on a 2004 workhorse W22 chassis. Consumer feels that because of the defective calipers he should not have to incur the repair expense, since he received a recall notice. *Tgw the consumer stated it was discovered that all four calipers were defective, which caused the…
2004 dolphin motor home on a 2004 workhorse W22 chassis. Consumer feels that because of the defective calipers he should not have to incur the repair expense, since he received a recall notice. *Tgw the consumer stated it was discovered that all four calipers were defective, which caused the pistons to hold the brake pads out and rub, which generated heat. the heat caused all four rotors to crack, which in turn wore out the disc pads. *Jb
- Service brakes, hydraulic
2004 workhorse W22 chassis. consumer states the right rear brake rotor froze causing a burning smell. Sent the coach in for repair and was charged for the repair. He feels that the failure was a cause from the recall. *kb the consumer stated a week after the rv was inspected, the ABS light illuminated. The consumer was charged for the replacement of the ABS sensor, rotors, pads and calipers. *jb
- Service brakes, hydraulic
2004 winnebago adventurer on a workhorse W22 chassis. Consumer states that his rv falls under the workhorse brake recall. *kb the consumer stated all four brake discs were cracked. *Jb
- Service brakes, hydraulic
2004 pace arrow on a 2004 workhorse W22 chassis. Consumer states brake failure *tgw the consumer was informed by the repair shop that a recall had been issued regarding the brakes. The consumer stated he never received a recall letter in the mail. several weeks later, the consumer received the…
2004 pace arrow on a 2004 workhorse W22 chassis. Consumer states brake failure *tgw the consumer was informed by the repair shop that a recall had been issued regarding the brakes. The consumer stated he never received a recall letter in the mail. several weeks later, the consumer received the recall letter in the mail. the repair shop contacted the consumer to inform him the left front brake was not eligible for replacement under the recall. *Jb
- Equipment · Equipment › Recreational vehicle/trailer
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…
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 high temperature censor needs to be repaired again. the manufacturer was contacted, but the contact was not able to get a live operator. the current and failure mileage was approxiametly 47,000. bw updated 01/24/11 *bf
- Service brakes, air
Tl*the contact owns a 2004 fleetwood southland motor home with a 2004 workhorse W22 chassis. recall nhtsa#09v198000; service brakes, air which was related to the calipers that were cracked, over heating and sticking. The failure also caused the rotors to crack which rendered the vehicle…
Tl*the contact owns a 2004 fleetwood southland motor home with a 2004 workhorse W22 chassis. recall nhtsa#09v198000; service brakes, air which was related to the calipers that were cracked, over heating and sticking. The failure also caused the rotors to crack which rendered the vehicle undrivable. After the dealer replaced the calipers they found additional damage on the rotors. The contact was billed double to repair the additional brake damage which should be a part of the recall. The manufacturer was contacted and stated that they would not replace the rotors because they were not covered by the warranty. The contact was responsible for the repair cost. The failure mileage was 24,127.
- Service brakes, hydraulic
2004 fleetwood pace arrow with a 2004 workhorse W22 chassis. Consumer states problem with brakes *tgw the consumer stated he has experienced three issues with the brakes; the first incident occurred in april 2009. When he applied the brake, the pedal went to the floor, but he was able to pump the…
2004 fleetwood pace arrow with a 2004 workhorse W22 chassis. Consumer states problem with brakes *tgw the consumer stated he has experienced three issues with the brakes; the first incident occurred in april 2009. When he applied the brake, the pedal went to the floor, but he was able to pump the brake pedal and was able to come to a stop. He discovered the brake reservoir was low. The second issue occurred in may 2010. While driving, the ABS light illuminated and again the brake fluid was low. There was also a heavy odor of burning brakes. The rv was taken to a repair shop. The consumer was informed the front brakes and calipers were dragging and there was a recall regarding the issue. the repair shop replaced both front brake pads and calipers and only the left front wheel speed sensor. The consumer was advised that the right front wheel speed sensor was damaged, but workhorse would not cover it. The third incident, the ABS light illuminated again and the brake fluid was low. The consumer took the rv to a repair shop. Upon inspection, the mechanic found both rear speed sensors were shorted out and that workhorse would not cover the repair. *Jb
- Service brakes, hydraulic
Consumer requests reimbursement for brake related failures to coach *tgw the brake fluid leaking from the right front wheel was found to be oil from the overheated hubs. The oil filled hubs plastic caps melted when the calipers froze and the brake drag overheated the rotors and melted the wheel speed sensors. the consumer stated the same symptoms have returned again. *Jb
- Service brakes, hydraulic
TL* the contact owns a 2005 thor windsport motor home with a 2004 W22 workhorse chassis. The contact stated she received notification of an unknown recall for the brakes of the workhorse chassis. The dealer advised that there were no replacement parts available to make repairs on the vehicle. The…
TL* the contact owns a 2005 thor windsport motor home with a 2004 W22 workhorse chassis. The contact stated she received notification of an unknown recall for the brakes of the workhorse chassis. The dealer advised that there were no replacement parts available to make repairs on the vehicle. The manufacturer confirmed that the parts were not available abd could not provide a time when they would become available. The failure mileage was not available.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- 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…
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.
Every Workhorse W22 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.