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#BS-2004-WORCHA-5BFA

2004 Workhorse Chassis

Based on reports from 44 owners and 1 recall for this exact model.

Complaints

Crashes

Fires

Recalls

TSBs

🟢

Preliminary Verdict

Proceed with Caution

Based on 44 complaints, 0 crashes, 2 fires, and 1 recalls.

See full verdict with buy/skip conditions

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Mechanic Inspection Checklist

!Check the BrakesHIGH

26 owners reported brakes issues — failures commonly reported around 17K miles.

!Inspect the ElectricalMED

Look for symptoms of wear and premature failure

+ 6 more items in full checklistUnlock

Failure Timeline by Mileage

0–30K

30–60K

60–90K

90–120K

120–150K

150K+

Peak failure range: 0–30K miles (27 reports) • Median: 17K miles

Full report: which components fail at each mileageUnlock

30,000-Mile Cost Projection

Best Case

$X,XXX

Most Likely

$X,XXX

Worst Case

$X,XXX

Top cost driver: Brakes (26 reports).

Includes fuel costs, common repairs, and recall riskUnlock

Also in your report

Owner Intelligence

AI-synthesized themes from real complaints

Buyer Lot Checklist

Questions, test drive checks, walk-away triggers

Negotiation Talking Points

Data-backed dollar deductions

Buy / Skip Verdict

Final recommendation with conditions

10 sections total in the full reportUnlock all

Where the complaints fall

Brakes26 (59%)

Electrical5 (11%)

Service Brakes, Hydraulic:foundation Components:disc:caliper2 (5%)

Engine2 (5%)

Engine And Engine Cooling:engine1 (2%)

Service Brakes, Hydraulic:foundation Components:disc:pads1 (2%)

Wheels:rim1 (2%)

Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:abs Warning Light1 (2%)

2004 Workhorse Chassis: Known Issues & Problem Areas

Brakes Issues

Brakes complaints account for 59% of all reports filed for the 2004 Workhorse Chassis, with 26 owners filing complaints with NHTSA. The median mileage at time of complaint is 17,000 miles, suggesting issues tend to surface around the 17K-mile mark.

Electrical Issues

Electrical complaints account for 11% of all reports filed for the 2004 Workhorse Chassis, with 5 owners filing complaints with NHTSA. Owners should pay attention to electrical-related symptoms during test drives and pre-purchase inspections.

Service Brakes, Hydraulic:foundation Components:disc:caliper Issues

Service Brakes, Hydraulic:foundation Components:disc:caliper complaints account for 5% of all reports filed for the 2004 Workhorse Chassis, with 2 owners filing complaints with NHTSA. Owners should pay attention to service brakes, hydraulic:foundation components:disc:caliper-related symptoms during test drives and pre-purchase inspections.

Engine Issues

Engine complaints account for 5% of all reports filed for the 2004 Workhorse Chassis, with 2 owners filing complaints with NHTSA. Owners should pay attention to engine-related symptoms during test drives and pre-purchase inspections.

Data sourced from NHTSA owner complaints and community reports. The full report analyzes severity, repair costs, and failure patterns for each category.

Complaint trend by year

Complaints filed with NHTSA by year for the 2004 Workhorse Chassis. Recent trend: decreasing.

Don't negotiate blind — know what this car costs to own

Repair costs • Negotiation scripts • Mechanic checklist • Buy/skip verdict

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Recall History (1 recall)

04V195000Jan 2005

ELECTRICAL SYSTEM

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 BELOW A VOLTAGE OF 1.5V, THE BRAKE FAILURE LAMP AND ALARM WILL BE ACTIVATED. ALSO ACTIVATION OF THE ABS TELL TALE WHEN THE ABS IS NOT PROPERLY FUNCTIONING DOES NOT ALWAYS OCCUR.

Recall severity analysis & seller scripts

The full report rates each recall's severity and gives you scripts for asking the seller about recall completion.

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About this data

NHTSA Complaints

Federal database of owner-filed safety complaints. 44 records for this vehicle.

NHTSA Recalls

Manufacturer-issued safety recalls. 1 recall found for this vehicle.

Repair Cost Data

Real-world repair costs from owner reports and independent databases.

Other Workhorse Chassis Model Years

2004 2003

View all Workhorse Chassis years →

2004 Workhorse Chassis: Frequently Asked Questions

What is the most common problem with the 2004 Workhorse Chassis?

The most commonly reported issue with the 2004 Workhorse Chassis is related to the brakes, with 26 complaints filed with NHTSA.

Is the 2004 Workhorse Chassis reliable?

The 2004 Workhorse Chassis has 44 complaints, 0 crash reports, and 2 fire reports filed with NHTSA. The full report analyzes whether these numbers indicate real risk or are proportional to the vehicle’s popularity.

How much does it cost to fix 2004 Workhorse Chassis problems?

Repair costs vary by issue. The full BumperScan report includes detailed repair cost estimates (low/median/high) for every major issue, plus a 30,000-mile total cost of ownership projection.

Does the 2004 Workhorse Chassis have any recalls?

Yes, the 2004 Workhorse Chassis has 1 recall on record. The full report includes recall severity analysis and scripts for asking the seller about recall completion.

What mileage do Workhorse Chassis problems start?

Based on 37 complaints with mileage data, the median mileage at time of complaint is 17,000 miles. The highest concentration of reported issues occurs in the 0–30K mile range. The full report breaks down exactly which components fail at each mileage bracket.

What’s in the full report?

10 sections of AI analysis: severity-ranked issues, component scores (0-100), 30K-mile cost projection, failure timeline by mileage, recall details with seller scripts, owner sentiment analysis, mechanic checklist, buyer lot checklist, negotiation ammo with dollar figures, and a buy/skip verdict.

How is this different from free NHTSA data?

NHTSA gives you raw complaint text. BumperScan cross-references 2.1M+ complaints with community repair cost data, EPA fuel data, and recall records — then uses AI to synthesize it into actionable advice with dollar figures.

How is this different from Carfax?

Carfax is VIN-specific history ($45/report). BumperScan is model-level reliability intelligence — what problems this car is known for, what they cost, and whether you should buy it. Complementary, not competing.

What if the report isn’t useful?

100% money-back guarantee. If the report doesn’t help you make a more informed decision, we’ll refund you — no questions asked.

Get the Full 2004 Workhorse Chassis Report

10 sections of AI analysis based on 44 owner reports. Know before you buy.

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