Workhorse Chassis Problems by Model Year
NHTSA recorded 56 consumer complaints across the 2 model years of the Workhorse Chassis (2003–2004) that have at least 5 complaints. 2004 has the most, with 34. Across all years, the part named most often is brakes (43 mentions). Pick a model year below to see its parts, mileage, recalls and service bulletins.
All Chassis model years
Years with fewer than 5 complaints are not listed. The score compares years of the same model, allowing for the era and for how long each year has collected complaints: 50 is a typical year, lower means fewer complaints. It is not adjusted for sales volume.
| Year | Complaints | Median mi | Recalls | TSBs | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|
| 2004 | 34 | 17,000 | 1 | 1 | Not compared (before 2008) | Stable |
| 2003 | 22 | 20,311 | 1 | 2 | — | Falling |
Parts named most often, all years
Counts add up complaint mentions across the listed years. A complaint can name several parts.
- Brakes43 72%
- Electrical system5 8.3%
- Transmission and drivetrain4 6.7%
- Suspension2 3.3%
- Steering2 3.3%
- Engine cooling2 3.3%
- Wheels1 1.7%
- Visibility (wipers, defrost, mirrors)1 1.7%
Example complaints
One per model year, chosen for length and detail. Personal details are removed. They are consumer reports, not findings.
2004: “Recent discussion boards talked about the need to service the brakes on the Workhorse Chassis. Had the wheels pulled and the brakes examined. All four rotors were cracked, causing increased wear on the shoes and a dangerous condition. I replaced them at my own expense.”
NHTSA complaint #10257750, filed 2009-02, 37,000 miles2003: “On a recent trip to the florida keys the anti-lock brake light came on. I checked the brakes and they seemed alright for the rest of the trip. I made an appointment to correct this condition in jan '08. The repair facility advise that all the brakes had been overheated, found calipers seizing up damaged wheel speed sensors. They replaced calipers, rotors, pads and wheel speed sensors also drilled and installed a grease fitting on the service brake pedal bell crank to prevent future seizing and damage new brake components. I have the damaged parts.”
NHTSA complaint #10226637, filed 2008-05, 23,500 milesOther Workhorse models
316 complaintsWorkhorse P320032
29 complaintsWorkhorse W20
24 complaintsWorkhorse P30
5 complaints
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate. Methodology