2004 Workhorse Chassis Brakes Problems
- Complaints
- 27about this part
- Share
- 79%of 34 total for the year
- Median mileage
- 17,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 27 complaints about the brakes of the 2004 Workhorse Chassis, 79% of the 34 complaints for this model year. Where a mileage was given, the median is 17,000 miles. 2 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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 miles“Used brakes about four or five times at traffic lights, then started to smell brakes. Pulled off roadway soon as possible, right rear brake extremely hot. Waited about an hour and half for brakes to cool. Brakes fail every time driven since that first failure.”
NHTSA complaint #10321205, filed 2010-03, 10,000 miles“The contact owns a 2004 Workhorse Chassis. While driving 25 MPH, the contact discovered that the brakes were burning. The calipers became so hot, that the ABS sensor failed. The caliper, ABS sensor, and brake pads were all replaced at the cost of $1,539.04. The current mileage was 20,000 and failure mileage was 17,000. Updated 12-12-07. Updated”
NHTSA complaint #10202766, filed 2007-09, 17,000 miles“The contact owns a 2004 Workhorse pace arrow. While driving 50 MPH, he attempted to engage the brake pedal and heard a popping noise in the rear passenger side of the vehicle. The dealer inspected the vehicle and was unable to diagnose the failure. There were no repairs made to the vehicle. The failure has occurred approximately 15 times. The failure mileage was 10,000 and the current mileage was 20,000.”
NHTSA complaint #10315185, filed 2010-03, 10,000 miles“The contact owns a 2004 sun cruiser 1fg33b rv. The vehicle was equipped with the Workhorse custom brakes. While the contact was driving approximately 55 MPH, the brake pedal was applied with a delay in the response time. The failure occurred at any speed rate traveled. The driver smelled a strong odor coming from the brakes. The vehicle has not been diagnosed for the malfunction. The current and failure mileages were 24,000.”
NHTSA complaint #10319047, filed 2010-03, 24,000 milesBrakes: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2004 | 27 | 79% |
| 2003 | 16 | 73% |
Other parts of the 2004 Workhorse Chassis
5 complaintsEngine cooling
2 complaintsEngine
1 complaintsFuel system
1 complaintsSteering
1 complaintsTires
1 complaintsTransmission and drivetrain
1 complaintsWheels
1 complaints
← All problems reported for the 2004 Workhorse Chassis
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology