2004 Workhorse Chassis Problems
- Complaints
- 34filed with NHTSA
- Median mileage
- 17,000miles, 28 complaints with mileage
- Recalls
- 1campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Sources: NHTSA records for the 2004 Workhorse Chassis (complaints, recalls, investigations). Report an error
NHTSA recorded 34 consumer complaints for the 2004 Workhorse Chassis. The part named most often is brakes, with 27 complaints (79% of the total), followed by electrical system (5) and engine cooling (2). 28 of the complaints include a mileage, and 96% of those were filed for vehicles with under 50,000 miles; the median is 17,000 miles. Of all complaints, 2 a fire, according to the filers. NHTSA lists 1 recall campaign and 1 technical service bulletin for this model year. Electrical system complaints overlap with 1 recall campaign filed under the same part.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Brakes27 79%
- Electrical system5 15%
- Engine cooling2 5.9%
- Engine1 2.9%
- Fuel system1 2.9%
- Steering1 2.9%
- Tires1 2.9%
- Wheels1 2.9%
Example complaints
Brakes: “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 milesElectrical system: “Recall campaign 04v195000 concerning Workhorse fmvss 101 and 105 instrument cluster. The consumer was unable to get the dealer to honor this recall since mid february 2005. The consumer was informed that the dealer did not have the tool to insert the correct data into the ip cluster. The consumer found a dealer who was able to perform the recall repairs.”
NHTSA complaint #10119240, filed 2005-05Engine cooling: “Intermittently while driving at any speed the engine would go into reduced power mode with out warning. When this happened the vehicle was only in idle power. This problem has occurred twice since february of 2004. The dealer is examining the vehicle at this time.”
NHTSA complaint #10082083, filed 2004-08, 5,000 milesMileage when problems were reported
96% of the 28 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 11,000 and 30,000 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Recalls and investigations
- 04V195000Apr 22, 2004Electrical systemCovers: Workhorse Chassis 2003–2004
Certain chassis equipped with actia corporate instrument clusters fail to comply with the requirements of federal motor vehicle safety standard nos. 101 "controls and displays" and 105 "hydraulic and electric brake systems." if the brake fail input falls…
Recall details for the 2004 Workhorse Chassis → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 1 on record; the latest 1 are shown.
- 10202062Sep 3, 2021Engine cooling. As communicated previously, an issue discovered in DiagnosticLink version 8.14SP1 was fixed with the release of 8.14SP3 on August26. The issue related to incorrect parameter data being sent to the…
Other model years of the Workhorse Chassis
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2004 | 34 | 17,000 | 1 | — | — | Not compared (before 2008) | Stable |
| 2003 | 22 | 20,311 | 1 | — | — | — | Falling |
All Workhorse Chassis model years
Frequently asked questions
How many NHTSA complaints does the 2004 Workhorse Chassis have?
NHTSA recorded 34 consumer complaints for the 2004 Workhorse Chassis as of Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Workhorse Chassis is reported most often?
Brakes is named most often, in 27 complaints (79% of the total), followed by electrical system with 5.
Has the 2004 Workhorse Chassis been recalled?
NHTSA lists 1 recall campaign for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
At what mileage are problems with the 2004 Workhorse Chassis reported?
Among the 28 complaints that include a mileage, the median is 17,000 miles and the middle half falls between 11,000 and 30,000 miles; 96% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.