2004 Kenworth W900 recalls and problems

The 2004 Kenworth W900 has 12 recalls and 2 owner complaints on file with NHTSA; the most reported problem area is electrical system.

How the 2004 compares

Highest

Fewest complaintsMost complaints

Highest complaint count among 12 W900 model years — 2nd most.

12recalls

2complaints

0crashes

2fires

0injuries

—median miles

Owner complaints filed with NHTSA, not verified and not adjusted for sales. Ranking compares this model's own years only.

Does your car have an open recall?
Recalls apply to specific vehicles. Only a VIN lookup on NHTSA's official site shows whether yours is affected and still unrepaired.

Check your VIN →

12 recalls

Service Brakes

Jun 30, 2009 · NHTSA campaign 09V239000 · 3,423 vehicles

Problem: Kenworth is recalling 3,423 my 2004-2009 T2000, T800,T600, W900 and T660 vehicles. Increased brake excitation in a certain vehicle configuration which includes bendix drum brakes, wide base low profile single tires, and an AG400 or AG460 rear suspension, due to its unique brake clocking and cam tube length, can cause fatigue and cracking to brake assembly components.

Original NHTSA wording

KENWORTH IS RECALLING 3,423 MY 2004-2009 T2000, T800,T600, W900 AND T660 VEHICLES. INCREASED BRAKE EXCITATION IN A CERTAIN VEHICLE CONFIGURATION WHICH INCLUDES BENDIX DRUM BRAKES, WIDE BASE LOW PROFILE SINGLE TIRES, AND AN AG400 OR AG460 REAR SUSPENSION, DUE TO ITS UNIQUE BRAKE CLOCKING AND CAM TUBE LENGTH, CAN CAUSE FATIGUE AND CRACKING TO BRAKE ASSEMBLY COMPONENTS.

Risk: Cracking can cause a complete fracture of the cam tube, which could increase stopping distance and decrease parking brake hold capability.

Original NHTSA wording

CRACKING CAN CAUSE A COMPLETE FRACTURE OF THE CAM TUBE, WHICH COULD INCREASE STOPPING DISTANCE AND DECREASE PARKING BRAKE HOLD CAPABILITY.

Remedy & notes

Dealers will inspect the rear axle brakes assembly, replace cracked rear axle brakes assembly components where required, and install cam tube support brackets on all rear axle wheel ends free of charge. The recall is expected to begin or before July 25, 2009. Owner May contact Kenworth at 1-425-828-5440.

Paccar recall no. 09KW7.owners May also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to <a href=http://www.safercar.gov>http://www.safercar.gov</a> .

Suspension

Sep 24, 2008 · NHTSA campaign 08V485000 · 130 vehicles

Problem: Paccar is recalling 130 my 2004-2009 T2000, T800, T600, W900 and T660 Kenworth trucks built with an AG400 rear suspension, long stroke brake chambers, and wide base tires (super singles). These vehicles May develop an increase in lateral and vertical axle movement. This movement May cause part or parts of the brake assembly (brake cam tube support, brake chamber bracket, brake chamber, brake spider) to develop fatigue cracks, possibly resulting in the failure of the part or parts within the brake assembly.

Original NHTSA wording

PACCAR IS RECALLING 130 MY 2004-2009 T2000, T800, T600, W900 AND T660 KENWORTH TRUCKS BUILT WITH AN AG400 REAR SUSPENSION, LONG STROKE BRAKE CHAMBERS, AND WIDE BASE TIRES (SUPER SINGLES). THESE VEHICLES MAY DEVELOP AN INCREASE IN LATERAL AND VERTICAL AXLE MOVEMENT. THIS MOVEMENT MAY CAUSE PART OR PARTS OF THE BRAKE ASSEMBLY (BRAKE CAM TUBE SUPPORT, BRAKE CHAMBER BRACKET, BRAKE CHAMBER, BRAKE SPIDER) TO DEVELOP FATIGUE CRACKS, POSSIBLY RESULTING IN THE FAILURE OF THE PART OR PARTS WITHIN THE BRAKE ASSEMBLY.

Risk: A failure May reduce vehicle brake performance, increasing the risk of a crash.

Original NHTSA wording

A FAILURE MAY REDUCE VEHICLE BRAKE PERFORMANCE, INCREASING THE RISK OF A CRASH.

Remedy & notes

Dealers will install the cam tube support brackets on all of the rear axle wheel ends. Inspect the rear axle brake assembly and replace it if cracked. The recall is expected to begin during November 2008. Owners May contact Kenworth at 1-425-828-5440.

Kenworth recall no. 08KWB. Customers May contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

Power Train

Mar 16, 2007 · NHTSA campaign 07V107000 · 4,592 vehicles

Problem: On certain trucks, the wiring, parts, or transmission programming required for the auto neutral feature to function as designed were either not installed, connected, or programmed properly.

Original NHTSA wording

ON CERTAIN TRUCKS, THE WIRING, PARTS, OR TRANSMISSION PROGRAMMING REQUIRED FOR THE AUTO NEUTRAL FEATURE TO FUNCTION AS DESIGNED WERE EITHER NOT INSTALLED, CONNECTED, OR PROGRAMMED PROPERLY.

Risk: If any of these conditions exists, the transmission will not automatically shift into neutral when left in drive with the parking brake set engaged. The vehicle could move without warning increasing the risk of a crash.

Original NHTSA wording

IF ANY OF THESE CONDITIONS EXISTS, THE TRANSMISSION WILL NOT AUTOMATICALLY SHIFT INTO NEUTRAL WHEN LEFT IN DRIVE WITH THE PARKING BRAKE SET ENGAGED. THE VEHICLE COULD MOVE WITHOUT WARNING INCREASING THE RISK OF A CRASH.

Remedy & notes

Dealers will inspect the affected vehicles to ensure the auto neutral feature functions properly and, if needed, will make the necessary repairs free of charge. The recall began on May 9, 2007. Owners May contact Kenworth at 425-828-5440.

Kenworth recall no. 07KW3.customers May contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

Engine

Dec 22, 2005 · NHTSA campaign 05V570000 · 30,995 vehicles

Problem: On certain tractors equipped with caterpillar diesel engines, the variable valve actuation oil line May wear against the sharp edge of the cylinder head if not positioned correctly.

Original NHTSA wording

ON CERTAIN TRACTORS EQUIPPED WITH CATERPILLAR DIESEL ENGINES, THE VARIABLE VALVE ACTUATION OIL LINE MAY WEAR AGAINST THE SHARP EDGE OF THE CYLINDER HEAD IF NOT POSITIONED CORRECTLY.

Risk: The oil line May be cut on the cylinder head causing an oil leak and a possible fire.

Original NHTSA wording

THE OIL LINE MAY BE CUT ON THE CYLINDER HEAD CAUSING AN OIL LEAK AND A POSSIBLE FIRE.

Remedy & notes

Caterpillar, in conjunction with paccar, will be conducting the owner notification and remedy for this campaign free of charge. Owners May call caterpillar at 309-675-6496, Kenworth at 425-828-5440, or Peterbilt at 940-591-4201.

Kenworth recall no. 05KW7 and Peterbilt recall no. 1205E.customers May also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236(tty 1-800-424-9153), or go to http://www.safercar.gov.

Suspension

Apr 28, 2005 · NHTSA campaign 05V189000 · 1,026 vehicles

Problem: On certain heavy duty class 8 trucks, the suspension has transverse beam castings that May fracture under normal loads. If a casting breaks when the vehicle is traveling on a roadway there is the potential for pieces of the casting to become projectiles and the suspension's transverse beam May drop down low enough to contact the road surface.

Original NHTSA wording

ON CERTAIN HEAVY DUTY CLASS 8 TRUCKS, THE SUSPENSION HAS TRANSVERSE BEAM CASTINGS THAT MAY FRACTURE UNDER NORMAL LOADS. IF A CASTING BREAKS WHEN THE VEHICLE IS TRAVELING ON A ROADWAY THERE IS THE POTENTIAL FOR PIECES OF THE CASTING TO BECOME PROJECTILES AND THE SUSPENSION'S TRANSVERSE BEAM MAY DROP DOWN LOW ENOUGH TO CONTACT THE ROAD SURFACE.

Risk: This could cause sparks that could potentially ignite and cause a fire.

Original NHTSA wording

THIS COULD CAUSE SPARKS THAT COULD POTENTIALLY IGNITE AND CAUSE A FIRE.

Remedy & notes

Dealers will inspect and replace the defective transverse beam assemblies free of charge. The recall began on June 10, 2005, with letters being mailed to Peterbilt owners; and on June 17, 2005, for Kenworth owners. Owners May contact Peterbilt at 940-591-4201 or Kenworth at 425-828-5440.

Peterbilt recall no. 405-B and Kenworth recall no. 05KW3.customers May also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.

Engine

Mar 4, 2005 · NHTSA campaign 05V084000 · 39 vehicles

Problem: On certain trucks equipped with webasto heaters, the burner tubes are made of material that does not meet specifications and could fail prematurely.

Original NHTSA wording

ON CERTAIN TRUCKS EQUIPPED WITH WEBASTO HEATERS, THE BURNER TUBES ARE MADE OF MATERIAL THAT DOES NOT MEET SPECIFICATIONS AND COULD FAIL PREMATURELY.

Risk: Should the burner tube fail, the coolant heater could overheat, possibly resulting in a fire.

Original NHTSA wording

SHOULD THE BURNER TUBE FAIL, THE COOLANT HEATER COULD OVERHEAT, POSSIBLY RESULTING IN A FIRE.

Remedy & notes

Dealers will replace the suspected defective parts free of charge. The recall began on April 4, 2004. Owners May contact Kenworth at 425-828-5440 or Peterbilt at 940-591-4201.

Kenworth's recall no. 05KW1 & Peterbilt's no. 305-A.customers May also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.

Electrical System

Dec 10, 2004 · NHTSA campaign 04V580000 · 4,322 vehicles

Problem: On certain trucks, the power feed harness P92-1993 terminals were not properly crimped.

Original NHTSA wording

ON CERTAIN TRUCKS, THE POWER FEED HARNESS P92-1993 TERMINALS WERE NOT PROPERLY CRIMPED.

Risk: This could lead to intermittent power loss affecting the electrical system and possibly result in a fire.

Original NHTSA wording

THIS COULD LEAD TO INTERMITTENT POWER LOSS AFFECTING THE ELECTRICAL SYSTEM AND POSSIBLY RESULT IN A FIRE.

Remedy & notes

Dealers will replace the harness. The recall began January 13, 2005. Owners should contact Kenworth at 1-425-828-5440.

Paccar/Kenworth recall no. 04KW8.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Structure

Nov 2, 2004 · NHTSA campaign 04V533000 · 2,851 vehicles

Problem: On certain trucks, some of the huck bolts on the cab May not have been properly installed.

Original NHTSA wording

ON CERTAIN TRUCKS, SOME OF THE HUCK BOLTS ON THE CAB MAY NOT HAVE BEEN PROPERLY INSTALLED.

Risk: If the huck bolts are not properly installed, in an extreme loading condition (such as frontal and/or side impact or a vehicle rollover situation), the cab structure could be compromised and not provide adequate protection for the occupant increasing the risk of personal injury.

Original NHTSA wording

IF THE HUCK BOLTS ARE NOT PROPERLY INSTALLED, IN AN EXTREME LOADING CONDITION (SUCH AS FRONTAL AND/OR SIDE IMPACT OR A VEHICLE ROLLOVER SITUATION), THE CAB STRUCTURE COULD BE COMPROMISED AND NOT PROVIDE ADEQUATE PROTECTION FOR THE OCCUPANT INCREASING THE RISK OF PERSONAL INJURY.

Remedy & notes

Dealers will inspect and replace the huck bolts on the cab attaching structure of the left-hand door aperture, if necessary. The recall began on November 19, 2004. Owners should contact Kenworth at 425-828-5440.

Kenworth's recall no. 04KW7.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Power Train

Sep 13, 2004 · NHTSA campaign 04V449000 · 203 vehicles

Problem: On certain trucks built with the optional dana spl driveline, the u-joint fasteners at the output yoke of the transmission were not properly tightened.

Original NHTSA wording

ON CERTAIN TRUCKS BUILT WITH THE OPTIONAL DANA SPL DRIVELINE, THE U-JOINT FASTENERS AT THE OUTPUT YOKE OF THE TRANSMISSION WERE NOT PROPERLY TIGHTENED.

Risk: If the u-joints were to become loose, a portion of the driveline could become detached from the vehicle and fall out from under the vehicle, which could cause a crash.

Original NHTSA wording

IF THE U-JOINTS WERE TO BECOME LOOSE, A PORTION OF THE DRIVELINE COULD BECOME DETACHED FROM THE VEHICLE AND FALL OUT FROM UNDER THE VEHICLE, WHICH COULD CAUSE A CRASH.

Remedy & notes

Dealers will verify the torque of the u-joint fasteners. Parts showing excessive wear will be replaced. The recall began on November 12, 2004. Owners should contact Kenworth at 1-425-828-5440.

Kenworth recall no.04KW6.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Electrical System

Jul 21, 2004 · NHTSA campaign 04V360000 · 15 vehicles

Problem: On certain trucks equipped with a combination of caterpillar C11/C13 engines and an optional leece neville brushless alternator, a chaffing point May exist between a heat shield on the engine and the wiring for the alternator.

Original NHTSA wording

ON CERTAIN TRUCKS EQUIPPED WITH A COMBINATION OF CATERPILLAR C11/C13 ENGINES AND AN OPTIONAL LEECE NEVILLE BRUSHLESS ALTERNATOR, A CHAFFING POINT MAY EXIST BETWEEN A HEAT SHIELD ON THE ENGINE AND THE WIRING FOR THE ALTERNATOR.

Risk: This could lead to an electrical short or arc situation which could result in an engine fire.

Original NHTSA wording

THIS COULD LEAD TO AN ELECTRICAL SHORT OR ARC SITUATION WHICH COULD RESULT IN AN ENGINE FIRE.

Remedy & notes

Dealers will change the alternator to a brush-type alternator that is shorter in length and provide the necessary clearance to all surrounding components. The recall began August 31, 2004. Owners should contact Kenworth at 1-425-828-5440.

Paccar/Kenworth recall no. 04KW3.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Equipment

Jul 15, 2004 · NHTSA campaign 04V356000 · 92 vehicles

Problem: Certain trucks fail to conform to the requirements of federal motor vehicle safety standard no. 120, 'tire selection and rims for motor vehicles other than passenger cars.' the tire pressure was omitted from the vehicle's certification label.

Original NHTSA wording

CERTAIN TRUCKS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, 'TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS.' THE TIRE PRESSURE WAS OMITTED FROM THE VEHICLE'S CERTIFICATION LABEL.

Risk: If the tire is operated in an under-inflated condition, the load carrying capacity of the vehicle May be compromised, increasing the risk of a crash.

Original NHTSA wording

IF THE TIRE IS OPERATED IN AN UNDER-INFLATED CONDITION, THE LOAD CARRYING CAPACITY OF THE VEHICLE MAY BE COMPROMISED, INCREASING THE RISK OF A CRASH.

Remedy & notes

Owners will be provided with a corrected label. The recall began August 12, 2004. Owners should contact Kenworth at 1-425-828-5440.

Paccar/Kenworth recall no. 04KW2.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Electrical System

Apr 12, 2004 · NHTSA campaign 04V174000 · 25 vehicles

Problem: Certain trucks equipped with eaton fuller ultrasonic transmissions fail to comply with the requirements of federal motor vehicle safety standard no. 102, "transmission shift lever sequence, starter interlock and transmission braking effect." the cab transmission harness could have been incorrectly wired during production installation.

Original NHTSA wording

CERTAIN TRUCKS EQUIPPED WITH EATON FULLER ULTRASONIC TRANSMISSIONS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 102, "TRANSMISSION SHIFT LEVER SEQUENCE, STARTER INTERLOCK AND TRANSMISSION BRAKING EFFECT." THE CAB TRANSMISSION HARNESS COULD HAVE BEEN INCORRECTLY WIRED DURING PRODUCTION INSTALLATION.

Risk: This could cause the neutral start feature of the transmission to disable allowing the vehicle to start in gear increasing the potential for a crash.

Original NHTSA wording

THIS COULD CAUSE THE NEUTRAL START FEATURE OF THE TRANSMISSION TO DISABLE ALLOWING THE VEHICLE TO START IN GEAR INCREASING THE POTENTIAL FOR A CRASH.

Remedy & notes

Dealers will repair the connections in the wiring harness if necessary. Owner notification began on May 7, 2004. Owners should contact Kenworth at 1-425-828-5440.

Kenworth recall no. 04KW1.customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Recall text as published by NHTSA and the manufacturer.

What owners complain about

Electrical System1

Tires1

Owner complaints filed with NHTSA; one complaint can name several areas. Not verified by NHTSA.

2004 vs. other Kenworth W900 years

Owner complaints by model year; the darker bar is the 2004. Click a bar to switch year.

Questions

Does the 2004 Kenworth W900 have recalls?

Yes — NHTSA lists 12 recall campaigns covering the 2004 Kenworth W900, the latest from Jun 30, 2009 (service brakes). A recall applies to specific vehicles: enter your VIN at nhtsa.gov/recalls to see whether yours is affected and still open.

What are the most common problems with the 2004 Kenworth W900?

Owner complaints filed with NHTSA most often mention electrical system (1), tires (1). Complaints are consumer reports and are not verified by NHTSA.