The 2005 Workhorse P42 is a robust commercial chassis, serving as the foundation for a variety of medium-duty applications, most notably delivery step vans (like UPS or FedEx trucks) and Class A motorhomes. Primarily offered as a chassis-cab, it wasn't sold with "trims" in the traditional sense, but rather defined by its Gross Vehicle Weight Rating (GVWR) capability within the P-series lineup, which spanned many years. Its popularity stems from its durable construction, powerful General Motors Vortec V8 engine, and reliability as a workhorse, making it a staple for fleets and RV manufacturers.
The Good
The Workhorse P42 offers strong, proven performance from its GM powertrain, ensuring reliability and robust hauling capacity critical for commercial use. Its utilitarian design prioritizes function over form. While comfort is basic in commercial applications, its reputation for durability and readily available parts translates to excellent long-term value. For RVers, it represents a sturdy, dependable platform for adventure; for businesses, a practical, hardworking asset.
The Bad
Known weaknesses for the 2005 Workhorse P42 include notoriously poor fuel economy due to its heavy-duty nature and large engine. The ride quality can be stiff, and cabin noise levels are high in commercial variants. Crucially, the P42 chassis is known for specific issues with its Bosch brake system, including caliper sticking and premature wear, requiring vigilant maintenance or upgrades.
2005 Workhorse P42: Quick Overview
- Engine Options: The primary engine for the 2005 Workhorse P42 chassis was the General Motors 8.1L (496 cu in) Vortec L18 V8 gasoline engine. Some less common configurations or larger Workhorse chassis might have offered diesel options like the Duramax, but the 8.1L gas V8 was prevalent for the P42 range. This engine is renowned for its torque and durability in heavy-duty applications.
- Horsepower: The 8.1L Vortec V8 typically produced around 340 horsepower and a substantial 455 lb-ft of torque, providing ample power for its intended commercial and RV applications.
- Fuel Economy: Fuel economy is a significant weak point, as expected for a heavy-duty commercial chassis powered by a large V8. Owners generally report figures in the range of 6-10 miles per gallon (MPG), heavily dependent on load, driving conditions, and body type.
- 0-60 Times: 0-60 mph times are not a relevant performance metric for the Workhorse P42 chassis. This vehicle is designed for hauling and towing heavy loads efficiently, not for acceleration or speed.
- Towing Capacity: Towing capacity is substantial but highly dependent on the final upfit (body type, weight) and the specific Gross Vehicle Weight Rating (GVWR) and Gross Combined Weight Rating (GCWR) of the completed vehicle. When configured as a Class A motorhome or step van, the chassis itself is capable of handling significant trailer weights, often in the 5,000 to 10,000+ pound range with appropriate hitches and braking systems.
- Trim-Level Features: The Workhorse P42 did not feature "trim levels" like passenger cars. Instead, features were focused on the commercial chassis's utility and heavy-duty components. Key chassis features include: a robust ladder frame, heavy-duty suspension components (leaf springs, solid axles), powerful hydraulic braking system (often Bosch), automatic transmission (typically an Allison 1000 or 2000 series, known for reliability), heavy-duty cooling system, and various GVWR options (the '42' in P42 often refers to a GVWR like 14,200 lbs or similar in thousands of lbs). The "cab" of a step van would include basic instrumentation, durable seating, and often air conditioning and power steering as options. RV builders would then integrate their own cabins and amenities onto this base.
2005 Workhorse P42 Specifications
Vehicle Information
| Year | 2005 |
| Make | Workhorse |
| Model | P42 |
| Trim | - |
| Style | - |
| Type | Bus |
| Category | P42 "P" Special Purpose Vehicle Chassis |
Manufacturing Details
| Made In | United States |
| Manufacturing City | UNION CITY |
Dimensions
| Doors | - |
| Curb Weight | - |
| Gross Vehicle Weight Rating | 16000 pounds |
| Overall Height | - |
| Overall Length | - |
| Overall Width | - |
| Wheelbase Length | - |
| Standard Seating | - |
Engine & Performance
| Engine | 6.0-L V-8 |
| Engine Size | 6L |
| Engine Cylinders | 8 |
| Transmission | - |
| Transmission Type | - |
| Transmission Speeds | - |
| Drivetrain | Rear-Wheel Drive |
Additional Features
| Anti-Brake System | - |
| Steering Type | - |
Pricing
| Manufacturer Suggested Retail Price (MSRP) | - |
| Invoice Price | - |
| Delivery Charges | - |
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What Problems Does the 2005 Workhorse P42 Have?
The 2005 Workhorse P42, while generally robust, has a well-documented history of specific issues, particularly concerning its braking system. The most frequently reported problem revolves around the Bosch hydraulic brake calipers, especially on the front axle. Owners often experience calipers sticking, leading to uneven pad wear, overheating, rotor warping, and even brake failure if left unaddressed. This issue prompted multiple recalls and extensive service campaigns. Owners of 2000-2007 Workhorse chassis, including the P42, have been particularly affected by these brake system concerns.
Beyond brakes, other long-term reliability concerns for the P42, though less critical, include:
Beyond brakes, other long-term reliability concerns for the P42, though less critical, include:
- Suspension Wear: Due to the heavy loads these chassis carry, components like leaf springs, shock absorbers, and various bushings can wear out over time, affecting ride quality and handling.
- Exhaust Manifold Leaks: The 8.1L Vortec engine, while powerful, can sometimes develop exhaust manifold leaks, characterized by a ticking sound, particularly when cold. This is a common GM big-block issue of the era.
- Engine Sensors: Like many vehicles of its age, O2 sensors, MAF sensors, and other emission-related components can fail, leading to "check engine" lights and potential performance issues.
- Electrical Gremlins: While not widespread, some owners report minor electrical issues, often related to aging wiring or connection points, which can be challenging to diagnose.
How long will the 2005 Workhorse P42 last?
The 2005 Workhorse P42 chassis, given its commercial design, is built for longevity. With diligent maintenance, it's common to see these vehicles, especially in fleet operations, achieve 200,000 to 300,000 miles or more, often serving 15-20+ years. RVs built on this chassis might have lower mileage but still demonstrate excellent long-term durability. The heavy-duty frame, 8.1L Vortec engine, and Allison transmission are exceptionally robust components. However, weaknesses emerge over time: the notorious brake system often requires significant attention or upgrades. Suspension components, such as shocks and bushings, wear under constant heavy loads. Exhaust systems can corrode, and interior components of commercial bodies will show considerable wear. Regular servicing, particularly of the brake system and chassis lubrication, is paramount for maximizing its extensive service life.
What Technology & Safety Features are Included?
As a 2005 commercial chassis, the Workhorse P42's built-in technology and entertainment features are rudimentary by modern standards. The "cockpit" of a typical step van built on this chassis would include a basic AM/FM radio, sometimes with a CD player. There was no integrated infotainment system, navigation, or advanced connectivity options available from the chassis manufacturer. Any more sophisticated entertainment or technology would be added by the body builder (for commercial vehicles) or RV manufacturer.
Driver-assistance features were extremely limited. The primary safety enhancement was an Anti-lock Braking System (ABS), which was becoming standard on many commercial vehicles by 2005. There were no modern driver-assistance technologies such as adaptive cruise control, lane-keeping assist, blind-spot monitoring, or automatic emergency braking. The focus was on robust mechanical reliability and fundamental safety.
Standard safety features included three-point seatbelts for the driver and front passenger(s). Airbags were typically limited to a driver's side airbag in most commercial cab configurations, or entirely absent in the most basic setups. The chassis's strength comes from its heavy-duty, full-frame construction, designed to withstand the rigors of commercial use and provide a sturdy base. For RV applications, the RV manufacturer would integrate additional safety measures specific to the coach body.
Optional features from Workhorse were generally limited to practical items like air conditioning, power steering, tilt steering, and perhaps upgraded seating for driver comfort. Crash-test ratings from agencies like NHTSA or IIHS are not applicable and were not conducted for bare commercial chassis like the Workhorse P42. Commercial vehicles are typically subject to different safety regulations and testing protocols, focusing on structural integrity and specific component performance rather than passenger-car-style crash test ratings.
Driver-assistance features were extremely limited. The primary safety enhancement was an Anti-lock Braking System (ABS), which was becoming standard on many commercial vehicles by 2005. There were no modern driver-assistance technologies such as adaptive cruise control, lane-keeping assist, blind-spot monitoring, or automatic emergency braking. The focus was on robust mechanical reliability and fundamental safety.
Standard safety features included three-point seatbelts for the driver and front passenger(s). Airbags were typically limited to a driver's side airbag in most commercial cab configurations, or entirely absent in the most basic setups. The chassis's strength comes from its heavy-duty, full-frame construction, designed to withstand the rigors of commercial use and provide a sturdy base. For RV applications, the RV manufacturer would integrate additional safety measures specific to the coach body.
Optional features from Workhorse were generally limited to practical items like air conditioning, power steering, tilt steering, and perhaps upgraded seating for driver comfort. Crash-test ratings from agencies like NHTSA or IIHS are not applicable and were not conducted for bare commercial chassis like the Workhorse P42. Commercial vehicles are typically subject to different safety regulations and testing protocols, focusing on structural integrity and specific component performance rather than passenger-car-style crash test ratings.
What Colors Options are Available?
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2005 Workhorse P42 Prices and Market Value
When new, the 2005 Workhorse P42 was sold as a chassis-cab to commercial body builders and RV manufacturers. A bare chassis price would be difficult to pinpoint, but a complete new step van built on a P42 could range from approximately $40,000 to $70,000+, while a new Class A motorhome utilizing this chassis could easily command $80,000 to over $200,000. On the current used market, prices vary wildly. A used P42 step van can range from $5,000 to $25,000+ depending heavily on condition, mileage, and specific upfit. Used RVs on the P42 chassis can be found anywhere from $20,000 to $80,000+, reflecting overall RV depreciation and condition. Depreciation for commercial vehicles is steep initially, then stabilizes. Factors affecting resale value include the overall mechanical condition (especially the brakes), mileage, presence of rust, the specific body/upfit, and maintenance records.
2005 Workhorse P42 Cost of Ownership
Long-term ownership of a 2005 Workhorse P42 can be costly. Insurance premiums will depend on its use (commercial fleet vs. RV), but generally reflect its heavy-duty nature. Fuel costs are a significant expense due to the large 8.1L V8's low fuel economy (6-10 MPG). Maintenance is routine for a commercial chassis, but parts for heavy-duty components can be more expensive than passenger car parts. Repairs, particularly for the known brake issues, can be substantial, requiring specialized components or upgraded kits. Overall, while the Workhorse P42 is reliable, its high fuel consumption and potential for costly brake system repairs make it a relatively expensive vehicle to own and operate, especially if not diligently maintained.
2005 Workhorse P42 Fuel Efficiency
Fuel Type
Gasoline
Fuel Capacity
-
City Mileage
-
Highway Mileage
-
2005 Workhorse P42 Warranty
Basic
Original warranty
0 months / No data
Estimated remaining
Expired
Powertrain
Original warranty
0 months / No data
Estimated remaining
Expired
Rust
Original warranty
0 months / No data
Estimated remaining
Expired
2005 Workhorse P42 Insurance
Insurance for a 2005 Workhorse P42 is moderately priced, reflecting its status as a Bus with strong safety ratings and
reasonable repair costs.
reasonable repair costs.
How Does the 2005 Workhorse P42 Compare to Other Bus?
The 2005 Workhorse P42 primarily competed against other major commercial chassis manufacturers, most notably the Ford E-Series Cutaway (E-350/E-450) and the Chevrolet Express/GMC Savana Cutaway. These platforms served similar markets for step vans, shuttle buses, and Class A RVs.
In terms of performance, the P42, with its standard 8.1L Vortec V8, generally offered comparable or superior power and torque compared to the gasoline engines in the E-Series (typically 6.8L V10 or 5.4L V8) and Express/Savana (6.0L V8 or 8.1L V8, though the 8.1L was less common on lighter GM cutaways). The P42 was often preferred for heavier applications due to its robust frame and engine. All were designed for commercial hauling rather than speed.
Features across these commercial chassis were inherently basic and utilitarian. All offered fundamental components like heavy-duty frames, hydraulic brakes, automatic transmissions, and basic driver amenities (power steering, optional AC). None boasted advanced infotainment or driver-assistance technologies common in passenger vehicles.
Reliability was generally good across the board for all three, provided they received proper commercial-grade maintenance. However, the Workhorse P42 gained notoriety for specific, persistent issues with its Bosch brake calipers, which led to significant owner frustration and recalls. While Ford and GM chassis also had their quirks, the brake issue was a prominent weak point for Workhorse. The Workhorse's Allison transmission and GM engine were highly reliable.
Price new would have been competitive across the segment, with chassis prices dictated by GVWR and options. On the used market, prices for completed vehicles (step vans or RVs) vary based on specific body, condition, and mileage. The brake issue on Workhorse models could sometimes lead to lower resale value unless proof of remediation was provided.
Recommended Alternatives: For similar applications, the Ford E-450 Cutaway is an excellent alternative, offering a robust platform, readily available parts, and a strong network of service centers. The Chevrolet Express 4500/GMC Savana 4500 Cutaway also provides a comparable heavy-duty platform. While both alternatives have their own maintenance considerations, they generally don't carry the same widely known brake system reputation as the Workhorse P42 of this era.
In terms of performance, the P42, with its standard 8.1L Vortec V8, generally offered comparable or superior power and torque compared to the gasoline engines in the E-Series (typically 6.8L V10 or 5.4L V8) and Express/Savana (6.0L V8 or 8.1L V8, though the 8.1L was less common on lighter GM cutaways). The P42 was often preferred for heavier applications due to its robust frame and engine. All were designed for commercial hauling rather than speed.
Features across these commercial chassis were inherently basic and utilitarian. All offered fundamental components like heavy-duty frames, hydraulic brakes, automatic transmissions, and basic driver amenities (power steering, optional AC). None boasted advanced infotainment or driver-assistance technologies common in passenger vehicles.
Reliability was generally good across the board for all three, provided they received proper commercial-grade maintenance. However, the Workhorse P42 gained notoriety for specific, persistent issues with its Bosch brake calipers, which led to significant owner frustration and recalls. While Ford and GM chassis also had their quirks, the brake issue was a prominent weak point for Workhorse. The Workhorse's Allison transmission and GM engine were highly reliable.
Price new would have been competitive across the segment, with chassis prices dictated by GVWR and options. On the used market, prices for completed vehicles (step vans or RVs) vary based on specific body, condition, and mileage. The brake issue on Workhorse models could sometimes lead to lower resale value unless proof of remediation was provided.
Recommended Alternatives: For similar applications, the Ford E-450 Cutaway is an excellent alternative, offering a robust platform, readily available parts, and a strong network of service centers. The Chevrolet Express 4500/GMC Savana 4500 Cutaway also provides a comparable heavy-duty platform. While both alternatives have their own maintenance considerations, they generally don't carry the same widely known brake system reputation as the Workhorse P42 of this era.
Final Verdict: Is the 2005 Workhorse P42 a Good Bus?
The 2005 Workhorse P42 is ideal for individuals or businesses seeking a highly durable, heavy-duty chassis capable of serving as a reliable foundation for a delivery step van, shuttle bus, or Class A motorhome. Its powerful 8.1L Vortec engine and Allison transmission are proven workhorses.
It is definitely worth buying on the used market, but only under specific conditions. A thorough pre-purchase inspection is critical, with an emphasis on the notorious Bosch brake system; ensure any recalls have been addressed or budget for potential upgrades/repairs. Detailed maintenance records are paramount. Avoid models with significant rust or neglected service. While its fuel economy is poor, its mechanical robustness means a well-maintained P42 can offer many more years of service for those needing serious hauling capability, making it a cost-effective, albeit thirsty, heavy-duty option.
It is definitely worth buying on the used market, but only under specific conditions. A thorough pre-purchase inspection is critical, with an emphasis on the notorious Bosch brake system; ensure any recalls have been addressed or budget for potential upgrades/repairs. Detailed maintenance records are paramount. Avoid models with significant rust or neglected service. While its fuel economy is poor, its mechanical robustness means a well-maintained P42 can offer many more years of service for those needing serious hauling capability, making it a cost-effective, albeit thirsty, heavy-duty option.
Jovan
Jovan specializes in interpreting vehicle records and making sense of VIN data. With over 10 years of experience in the automotive data industry, his work ensures that every report is clear, accurate, and useful for car buyers.