Western Star Conventional — Suspension
High risk
Aug 23, 1996
Model years: 1995, 1996
On certain trucks, the suspension equalizing beam shaft could fracture inside the beam at the toe of the weld due to the use of a non-conforming shaft. A single shaft failure could
Western Star Conventional — Brakes
High risk
Mar 26, 1996
Model years: 1995, 1996
Certain trucks were built without inversion valves. The inversion valve provides modulated spring brake application during emergency braking when the "A" portion of air the air bra
Western Star Conventional — Engine
High risk
Feb 2, 1996
Model years: 1995
On certain trucks, the throttle springs were manufactured such that the hooks at each end may have a tighter than required diameter. If the diameter of a hook is too tight it may b
Western Star Conventional — Structure
High risk
Jan 31, 1996
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Certain trucks may have been built with bare mufflers mounted at the back of the cab behind air shields. There is no heat shield to protect someone from contacting the hot muffler
Western Star Conventional — Brakes
High risk
Jul 20, 1995
Model years: 1995
On certain trucks, the air brake line gladhand connector plate screws were not properly heat treated after plating and could fail due to hydrogen embrittlement. This could result i
Western Star Conventional — Brakes
High risk
Mar 7, 1995
Model years: 1992, 1993, 1994, 1995
On certain trucks, the dryer cannot remove all of the moisture from the air. In a cold environment this moisture may freeze and effectively block the air lines downstream of the dr
Western Star Conventional — Brakes
High risk
Feb 23, 1995
Model years: 1987, 1988, 1989, 1990
On certain trucks, the brake return springs on the front brakes may contact the front hubs. Over time the hub may wear the spring shank to the point of spring failure. A piece of t
Western Star Conventional — Steering
High risk
Feb 10, 1995
Model years: 1994
On certain trucks, the steering knuckle (where the steering arm is installed) may not have had corrosion inhibiting grease removed prior to assembly. The joints may also have been
Western Star Conventional — Structure
High risk
Feb 8, 1995
Model years: 1990, 1991, 1992, 1993, 1994, 1995
On certain trucks, the upper bunk retaining straps may release without warning allowing the upper bunk to fall from its raised storage position to its "in use" position. If someone
Western Star Conventional — Steering
High risk
Dec 30, 1994
Model years: 1990, 1991, 1992, 1993, 1994
On certain trucks, the timing link ball stud may not be correctly seated in the slave gear pitman arm taper. This could allow the ball stud to turn in the pitman arm taper causing
Western Star Conventional — Engine
High risk
Dec 19, 1994
Model years: 1994
On certain trucks, residual stress on the Electronic Control Module (ECM) ground terminal may be sufficient to cause the terminal to crack and eventually fail. If this terminal fai
Western Star Conventional — Suspension
High risk
Nov 8, 1994
Model years: 1987, 1988, 1989, 1990, 1991, 1992
On certain trucks, the aluminum rear spring shackle brackets may have developed cracks which may lead to separation of the brackets from the frame rail. This could cause the suspen
Western Star Conventional — Brakes
High risk
May 6, 1994
Model years: 1992, 1993, 1994
On certain trucks, the air dryer relief valve may be susceptible to freezing. Freeze-up of the relief valve in conjunction with a blockage in the air line between the air dryer and
Western Star Conventional — Structure
High risk
Dec 7, 1993
Model years: 1986, 1987, 1988, 1989, 1990, 1991
On certain trucks, the grab handles may be susceptible to fatigue failure and may break at the bend radius near the upper mounting bolt hole. Failure during use could result in a f
Western Star Conventional — Other
High risk
Jul 14, 1993
Model years: 1991, 1992
Certain trucks do not comply with CMVSS 302 - Flammability. Each of the bunks has a mattress cover with ticking that does not comply with the requirements of the standard. The burn
Western Star Conventional — Engine
High risk
Mar 10, 1993
Model years: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992
On certain trucks, the electronic accelerator pedal on these may experience premature failure of the pedal return springs. If both springs fail, the pedal will not return to the id
Western Star Conventional — Powertrain
High risk
Oct 2, 1992
Model years: 1986, 1987, 1988, 1989, 1990
On certain trucks, the aluminum clutch release lever may fail as the result of stress corrosion due to continuous loading of the lever and exposure to road salt spray. This would r
Western Star Conventional — Suspension
High risk
Apr 11, 1991
Model years: 1989, 1990
On certain trucks used in logging operations, the Hendrickson HA-460 series #1 suspension spring hangers may fracture. Spring hanger failure could cause separation of vehicle compo
Western Star Conventional — Engine
High risk
Apr 11, 1991
Model years: 1989
On certain trucks, one or more of the foot pedal assembly return springs may fail. If both springs fail, the pedal may unexpectedly go to the full throttle position. This could res
Western Star Conventional — Brakes
High risk
Nov 28, 1990
Model years: 1988, 1989, 1990
On certain trucks, the battery cables and air lines may have been routed and clipped in such a way that downward movement of the transmission may cause the transmission rear suppor
Western Star Conventional — Engine
High risk
Dec 19, 1989
Model years: 1987, 1988, 1989
On certain trucks, the throttle return springs may fail during normal operation without prior warning. If both springs fail, the engine throttle may not return to the idle position
Western Star Conventional — Steering
High risk
Mar 28, 1989
Model years: 1988, 1989
Certain trucks could experience fatigue cracking of the axle beam which in turn could result in complete rupture of the forged centre section of the beam. A beam failure could resu
Western Star Conventional — Engine
High risk
Feb 9, 1989
Model years: 1988, 1989
On certain trucks, the throttle cable may fail in service due to vibrational fatigue between the cable end sleeve and hub. Such a failure could result in possible loss of vehicle c
Western Star Conventional — Steering
High risk
Jan 4, 1989
Model years: 1988
On certain trucks, the drag link may weaken as the result of contact with the steering box in a hard left hand turn with full compression of the front springs. This could result in
Western Star Conventional — Seats And Restraints
High risk
Nov 7, 1988
Model years: 1988
On certain trucks, the seatbelt assembly may go into a non-lock mode if the seat cushion presses against the retractor neck with sufficient pressure to cause the komfort-lok featur
Western Star Conventional — Steering
High risk
Aug 19, 1988
Model years: 1988
On certain trucks, internal failure of the TRW ROSS TAS65 steering gear mechanism can occur such that the gear binds and/or is unable to transmit torque between the input and outpu
Western Star Conventional — Steering
High risk
Aug 5, 1988
Model years: 1988
On certain trucks equipped with an Eaton model EFA-12, 13,200 pound, front steering axle, the steering arms could develop fatigue cracks. Thus there is a possibility of steering ar
Western Star Conventional — Other
High risk
Jul 18, 1988
Model years: 1987, 1988
Certain vehicles are equipped with stainless steel wrapped mufflers mounted vertically behind the cab with grabhandles attached to them for cab access. Persons using the grabhandle
Western Star Conventional — Engine
High risk
Jul 14, 1988
Model years: 1988
On certain trucks, the Cummins 1988NT engines may have been assembled with potentially defective oil cooler gaskets. During high load/high temperature operation, loss of lubricatin
Western Star Conventional — Engine
High risk
Feb 23, 1988
Model years: 1982, 1983, 1984, 1985, 1986, 1987, 1988
Certain trucks may have throttle return springs that could fail during normal operation without prior warning. If both springs fail, the engine throttle may not return to the idle
Western Star Conventional — Powertrain
High risk
Jan 18, 1988
Model years: 1986, 1987
On certain vehicles, the clutch release lever may have been weakened during manufacture and could fail at the clutch release shaft connection. This would result in a loss of clutch
Western Star Conventional — Suspension
High risk
Oct 9, 1987
Model years: 1984, 1985, 1986, 1987
On certain trucks, the top torque rods on the Chalmers 800 series suspensions may contain inadequate welds. This could cause the torque rod to fail without warning allowing the rea
Also affects: Western Star C.O.E.
Western Star Conventional — Suspension
High risk
Jul 31, 1987
Model years: 1985, 1986
On certain trucks, rear drive axles may have an incomplete weld between the axle housing and the suspension hanger brackets. After extended service, the partial weld may fail and c
Western Star Conventional — Brakes
High risk
Jun 12, 1987
Model years: 1985, 1986, 1987
On certain trucks, the brake pedal assembly used in the right hand station of vehicles built with dual drive option, may have been improperly welded. The weld that attaches the piv
Western Star Conventional — Suspension
High risk
May 28, 1987
Model years: 1985, 1986, 1987
On certain trucks, the Chalmers 1200 series air-ride suspension may develop cracks in the welded joints between the outrigger spring brackets and the main sawhorse "A" frames. Thes
Western Star Conventional — Fuel System
High risk
Mar 11, 1987
Model years: 1986
On certain trucks, aluminum fuel tanks may contain fuel pickup tubes with substandard welds that could crack and allow air to be drawn into the pump. This could cause the engine to
Western Star Conventional — Fuel System
High risk
Jan 29, 1986
Model years: 1983, 1984, 1985
On certain trucks, when a sentinal shutdown unit is activated due to the failure of a monitered system and blocks the engine fuel supply, the fuel pump continues to pump fuel and b
Western Star Conventional — Steering
High risk
Nov 7, 1985
Model years: 1978, 1979, 1980, 1981, 1982, 1983, 1984
On certain trucks, the pitman arm was undertorqued when installed on the sector shaft of the steering box. Separation of the pitman arm would result in loss of steering control.
Western Star Conventional — Seats And Restraints
High risk
Aug 22, 1985
Model years: 1983, 1984, 1985
On certain trucks, the lap belt may detach from the retractor assembly under severe decelerations.
Western Star Conventional — Other
High risk
May 22, 1985
Model years: 1984, 1985
On certain trucks, the hole in the throttle lever and the stop pin may be mismatched which could allow the pin to loosen and fall out. Should this happen the tension spring attache
Western Star Conventional — Suspension
High risk
May 21, 1985
Model years: 1983, 1984
On certain trucks, the Rockwell "FF" series front axle beam assemblies may contain cracks at the axle beam forged ends where the steering knuckles are attached by the king pins. Th
Western Star Conventional — Electrical
High risk
Dec 4, 1984
Model years: 1982, 1983, 1984
Certain trucks may have a defective ON-OFF toggle switch installation in the sleeper which may cause an intermittent short circuit which could lead to heat damage of the surroundin
Western Star Conventional — Other
High risk
Oct 11, 1984
Model years: 1983, 1984
On certain trucks, the governor flyweight shield may become loose or break off from the flyweight carrier due to an incorrect shield to carrier fit. The loose/broken shield may int
Western Star Conventional — Other
High risk
Feb 13, 1984
Model years: 1982, 1983
Certain vehicles equipped with an Eaton two-speed rear axles contain a ratio adapter attached to the rear of the speedometer and an air switch behind the dash which may come in con
Western Star Conventional — Brakes
High risk
May 2, 1983
Model years: 1982
On certain vehicles, the Rockwell front brake assemblies have a 6 inch diameter pilot hole to accommodate the front axle spindle which is 5 1/2 inches in diameter. On a braking app
Western Star Conventional — Suspension
High risk
Feb 17, 1983
Model years: 1975, 1976, 1977
Certain vehicles built with Rockwell SLHD model rear axles may experience a fracture and ultimate separation of the rear axle outer ends in the area of the spindle attachment to th
Also affects: White Conventional
Western Star Conventional — Steering
High risk
Mar 5, 1982
Model years: 1975, 1976, 1977, 1978, 1979, 1980, 1981
On certain trucks, binding bolts used to secure steering shaft yokes to their mating components may not have been tightened to specifications. Over or under tightened binder bolts
Also affects: Autocar C, Autocar Dc, Autocar S, White Conventional
Western Star Conventional — Steering
High risk
Dec 8, 1981
Model years: 1977, 1978
On certain trucks, the drag link adapter to the valve housing of the garrison G-21 series power steering control valve may loosen and eventually disengage resulting in loss of cont
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