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2004 Workhorse W22

Owner reports · Recalls · Investigations

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What owners reported most

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When problems were reported

Mileage at the reported incident

64 reports with mileage · 28 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Service Brakes, Hydraulic. Review the 74 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes. Review the 6 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 4 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

0 crash reports3 fire reports0 injury reports

What owners actually said

92 reports
32,700 miles · Aug 14, 2008
Service Brakes, Hydraulic

OPERATING A 2004 FLEETWOOD PACE ARROW 35G MOTORHOME ON A WORKHORSE CHASSIS W22, FLAT TOWING A 2002 HONDA CIVIC. TRAVELING RT 41 IN PA. FROM NEW JERSEY. I WAS OPERATING IN MILD TO LIGHT TRAFFIC ON A HILLY ROAD BETWEEN AVONDALE AND GAP, PA. AT FIRST I SMELLED WHAT I THINK WAS AND ELECTRICAL SCENT. SOON AFTER I LOSS BRAKE PEDAL …

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OPERATING A 2004 FLEETWOOD PACE ARROW 35G MOTORHOME ON A WORKHORSE CHASSIS W22, FLAT TOWING A 2002 HONDA CIVIC. TRAVELING RT 41 IN PA. FROM NEW JERSEY. I WAS OPERATING IN MILD TO LIGHT TRAFFIC ON A HILLY ROAD BETWEEN AVONDALE AND GAP, PA. AT FIRST I SMELLED WHAT I THINK WAS AND ELECTRICAL SCENT. SOON AFTER I LOSS BRAKE PEDAL PRESSURE. PUMPING THE PEDAL IMPROVED BRAKE USAGE. PERSONALLY EXAMINED THE MASTER AND ALL FOUR BRAKES UNDER THE MOTORHOME FOR FLUID LOSS. NONE OBSERVED NEXT DAY DROVE SHORT DISTANCE TO A QUALITY AUTO / TRUCK REPAIR IN GAP, PA. AND INFORMED THEM OF THE INCIDENT AND REQUESTED THEY SURVEY THE BRAKE SYSTEM FOR PROBLEMS. THEY FOUND NONE. DROVE BACK HOME TO EGG HARBOR TWP., NJ WITHOUT A PROBLEM. *TR

NHTSA ODI #10238343

23,400 miles · Aug 13, 2008
Service Brakes, Hydraulic

TOOK MOTORHOME (WORKHORSE W22 CHASSIS) TO GET GAS, APPROX 5 MILES. GOT GAS AND RETURNED. LITTLE TRAFFIC, FLAT ROAD, 45 MPH. UPON RETURN, BOTH FRONT BRAKE ROTORS WERE SMOKING. THIS FOLLOWS PREVIOUS FAILURES OF BOTH REAR BRAKES. MOTORHOME HAS LESS THAN 24,000 MILES AND HAS BEEN WELL MAINTAINED, INCLUDING TWO COMPLETE REPLACEMENTS…

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TOOK MOTORHOME (WORKHORSE W22 CHASSIS) TO GET GAS, APPROX 5 MILES. GOT GAS AND RETURNED. LITTLE TRAFFIC, FLAT ROAD, 45 MPH. UPON RETURN, BOTH FRONT BRAKE ROTORS WERE SMOKING. THIS FOLLOWS PREVIOUS FAILURES OF BOTH REAR BRAKES. MOTORHOME HAS LESS THAN 24,000 MILES AND HAS BEEN WELL MAINTAINED, INCLUDING TWO COMPLETE REPLACEMENTS OF BRAKE FLUID. NOTIFIED WORKHORSE AND THEY RESPONDED THAT THE VEHICLE IS OUT OF WARRANTY AND NOT INVOLVED IN ANY BRAKE RECALLS. THIS REPORT IS A DUPLICATE OF 10237294 WHICH WAS FILED UNDER THE MOTORHOME NAME INSTEAD OF THE WORKHORSE CHASSIS. *TR

NHTSA ODI #10238023

24,050 miles · Aug 12, 2008
Service Brakes, Hydraulic

ON SEP. 12 OF 2007, WE LEFT ON A TRIP FROM OUR HOME TO LAS VEGAS, NV. ON THE FIRST LEG OF OUR TRIP OUR WE NOTICED WE WERE GETTING VERY POOR GAS MILEAGE AND IT SEEMED LIKE OUR BRAKES WERE DRAGGING. WE PULLED OVER AT THE WELCOME CENTER IN LOUISIANA ON I-59. WE NOTICED THE REAR BRAKES SMELLED HOT. WHEN WE WENT BACK INTO THE MOTO…

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ON SEP. 12 OF 2007, WE LEFT ON A TRIP FROM OUR HOME TO LAS VEGAS, NV. ON THE FIRST LEG OF OUR TRIP OUR WE NOTICED WE WERE GETTING VERY POOR GAS MILEAGE AND IT SEEMED LIKE OUR BRAKES WERE DRAGGING. WE PULLED OVER AT THE WELCOME CENTER IN LOUISIANA ON I-59. WE NOTICED THE REAR BRAKES SMELLED HOT. WHEN WE WENT BACK INTO THE MOTORHOME AND STARTED IT BACK UP THE "ABS" WARNING LIGHT WAS ON. WE THEN CALLED A WORKHORSE SERVICE CENTER, ROSS DOWNING CHEVROLET. THE MECHANIC TOLD US TO WAIT FOR AN HOUR AND DRIVE IT TO HAMMOND TO THE DEALERSHIP AND HE WOULD WORK ON IT. THE MECHANIC REPLACED THE REAR ROTORS, CALIPERS, PADS AND WHEEL SENSORS, THEN RESET THE "ABS" WARNING LIGHT. ALL WAS GOOD UNTIL WE WENT OVER THE HOOVER DAM AND THE ABS LIGHT CAME BACK ON AND WE PULLED OVER AND LET THE BRAKES COOL DOWN AGAIN AND THEN DROVE TO OUR CAMPGROUND AT NELLIS AIR FORCE BASE IN LAS VEGAS. THEN ONCE WE WERE THERE WE CALLED AND MADE AN APPOINTMENT WITH FINDLAY RV. THEY REPLACED THE WHEEL SENSOR ON THE FRONT LEFT WHEEL. AND RESET THE CODES. THE DATE OF THE FRONT WHEEL INCIDENT WAS APPROX. SEP 21 2007. NOW FOR THE MOST RECENT INCIDENT. AUGUST 7, 2008, WE WERE TRAVELING TO BILOXI, MS FROM OUR HOME AND I NOTICED OUR GAS MILEAGE DECREASING AGAIN. WE PULLED OVER AND SMELLED THAT THE LEFT FRONT WHEEL AREA WAS HOT. WE LET THE BRAKES COOL AGAIN AND FROM OUR PREVIOUS EXPERIENCE AND BECAUSE WE ARE SO CLOSE TO HOME WE DECIDED TO JUST GO AHEAD AND STAY IN BILOXI BECAUSE I HAD AN APPOINTMENT AT THE VA CENTER IN BILOXI THE NEXT DAY. WE ARE GOING TO TAKE THE MOTORHOME TO A SERVICE CENTER TO HAVE THE "ABS" WARNING LIGHT CHECKED OUT AND REPAIRED. I BELIEVE THAT 3 TIMES IN A YEAR IS A BIT EXCESSIVE TO HAVE PROBLEMS WITH THE "ABS" SYSTEM AND NEEDS TO BE INVESTIGATED ESPECIALLY SINCE OUR MOTORHOME IS ONLY 4 YEARS OLD. ALSO, MY PARENTS OWN A 2003 WORKHORSE W22 CHASSIS ALSO AND HAVE HAD PROBLEMS WITH THEIR "ABS" WARNING LIGHT ALSO. *TR

NHTSA ODI #10237904

12,000 miles · Jul 31, 2008
Service Brakes, Hydraulic

OVERHEATING BRAKE PROBLEMS ON WORKHORSE W22 MOTORHOME CHASSIS (2004) 3RD TIME THIS HAS OCCURED. TWICE ON DIFFERENT WHEELS. *TR

NHTSA ODI #10236485

23,000 miles · Jul 4, 2008
Service Brakes, Hydraulic

THE LEFT REAR BRAKES LOCKED-UP CAUSING SMOKE TO AND THE STRONG ODOR OF BRAKE MATERIAL. I REMOVED THE CALIPER AND PUSHED THE PISTONS BAKE INTO THE CALIPER. THIS IS THE FIRST INCIDENT WITH THE BRAKES IN 23,000 MILES, BUT HAS BEEN AN ISSUE WITH THE WORKHORSE W-22 CHASSIS. *TR

NHTSA ODI #10233201

12,000 miles · Jun 29, 2008
Service Brakes, Hydraulic

MY WORKHORSE BRAKES WENT OUT, I ONLY HAD 12,000 MILES AT THE TIME ON MY NEW MOTORHOME. *TR

NHTSA ODI #10232642

16,450 miles · Jun 4, 2008
Service Brakes, Hydraulic

I HAD A PROBLEM AND COMPLAINT WITH THE BRAKES ON OUR WINNEBAGO MOTORHOME JUST AS DESCRIBED IN YOUR NHTSA ACTION EA07016. IT WAS DIFFICULT TO DUPLICATE JUST AS YOUR INVESTIGATION HAS FOUND. THIS FIRST HAPPENED IN NOVEMBER 2007 AND AGAIN IN APRIL 2008. I FOUND AN INDEPENDENT MOTORHOME REPAIR SHOP THAT HAD SEEN THIS COMPLAINT WI…

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I HAD A PROBLEM AND COMPLAINT WITH THE BRAKES ON OUR WINNEBAGO MOTORHOME JUST AS DESCRIBED IN YOUR NHTSA ACTION EA07016. IT WAS DIFFICULT TO DUPLICATE JUST AS YOUR INVESTIGATION HAS FOUND. THIS FIRST HAPPENED IN NOVEMBER 2007 AND AGAIN IN APRIL 2008. I FOUND AN INDEPENDENT MOTORHOME REPAIR SHOP THAT HAD SEEN THIS COMPLAINT WITH 2 PRIOR UNITS AND HAD REPAIRED THEM. KEN MEADS WITH MOTORHOME SERVICE IN HOT SPRINGS, ARKANSAS SEEMS VERY VERSED IN THIS PROBLEM. HIS NUMBER IS 501-609-0145. I AM NOT HAPPY WITH WORKHORSE OR BOSCH AS THEY SEEM TO THINK THIS IN NOT THEIR PROBLEM. I AM LOOKING FORWARD TO SOME TYPE OF RESOLUTION TO THIS PROBLEM AND RE-IMBURSEMENT OF MY EXPENSES FOR REPAIR. *TR

NHTSA ODI #10229938

13,574 miles · May 13, 2008
Service Brakes, Hydraulic

FRONT RIGHT BRAKE CALIPER LOCKED UP HEATING ROTOR AND DAMAGING PADS, ROTOR, AND ABS SENSOR. *TR

NHTSA ODI #10227661

6,500 miles · May 5, 2008
Service Brakes, Hydraulic

2004 WORKHORSE W22 MOTORHOME CHASSIS. RIGHT REAR BRAKE SHOES NOT RELEASING FROM ROTOR CAUSING BRAKES TO OVER HEAT. DAMAGE UNKNOWN. RV SCHEDULED FOR INSPECTION MAY 6, 2008. 6500 MILES. DRIVEN ONLY OCCASIONALLY. *TR

NHTSA ODI #10226675

Mileage unknown · Apr 22, 2008
Service Brakes, Hydraulic

BRAKES LOCKED UP ON MY 2004 WORKHORSE W22 CHASSIS. I HAD TO REPLACE ALL 4 CALIPER, BRAKE PADS AND ALL 4 ABS WHEEL SENSORS. *TR

NHTSA ODI #10225338

Official recalls

2

09V110000 · Service Brakes, Hydraulic

Apr 3, 2009

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 & remedy

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.

06V225000 · Engine And Engine Cooling

Jun 20, 2006

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 & remedy

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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

EA07016 · Overheating Disc Brake Caliper

Opened Nov 16, 2007 · Closed Aug 19, 2009

Status: closed (inferred from source dates) · Service Brakes, Hydraulic

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.

Additional source detail variants (7)

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.

Service Brakes, Hydraulic

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.