Western Star CONVENTIONAL recalls by model year

Reported: 1988-02-26 (February 26, 1988) · Model years: 1983, 1984, 1985, 1986, 1987, 1988

THROTTLE RETURN SPRINGS MAY FAIL DURING NORMAL OPERATION WITHOUT PRIOR WARNING.

Consequence: IF BOTH SPRINGS FAIL, ENGINE THROTTLE MAY NOT RETURN TOIDLE POSITION WHEN THROTTLE FOOT PEDAL IS RELEASED; THIS COULD RESULT IN A LOSSOF VEHICLE CONTROL AND A CRASH.

Remedy: REPLACE THROTTLE RETURN SPRINGS.

Reported: 1992-10-08 (October 8, 1992) · Model years: 1985, 1986, 1987, 1988, 1989, 1990

PREMATURE FAILURE OF THE ALUMINUM CLUTCH RELEASE LEVER CAN OCCUR FROM STRESS CORROSION DUE TO CONTINUOUS LOADING OF THE LEVER AND EXPOSURE TO ROAD SALT SPRAY.

Consequence: IF THE FAILURE OCCURS DURING VEHICLE OPERATION, THECLUTCH IS RENDERED INOPERATIVE AND THE VEHICLE OPERATOR CANNOT CONTROL THEVEHICLE SPEED BY UP-SHIFTING OR DOWN-SHIFTING, WHICH MAY RESULT IN LOSS OFVEHICLE CONTROL.

Remedy: REPLACE THE ALUMINUM LEVER WITH AN IRON LEVER.

Reported: 1993-12-07 (December 7, 1993) · Model years: 1986, 1987, 1988, 1989, 1990, 1991

THE CAB ACCESS GRAB HANDLES HAVE THINNER THAN SPECIFIED WALL THICKNESS AND ARE SUSCEPTIBLE TO FATIGUE FAILURE BREAKING AT THE BEND RADIUS NEAR THE UPPER MOUNTING BOLT HOLE.

Consequence: FAILURE DURING USE OF THE GRAB HANDLES CAN CAUSE AUSER TO FALL RESULTING IN PERSONAL INJURY.

Remedy: WESTERN STAR DEALERS WILL REMOVE AND DESTROY THE RECALLED GRAB HANDLES. NEW HANDLES WILL BE INSTALLED ON THESE VEHICLES.

Reported: 1988-01-18 (January 18, 1988) · Model years: 1987

THE C SHAPED CLUTCH RELEASE LEVER MAY HAVE BEEN WEAKENED DUE TO CASTING IMPERFECTIONS.

Consequence: CLUTCH LEVER MAY FAIL RESULTING IN LOSS OF CLUTCHCONTROL WHICH COULD RESULT IN LOSS OF VEHICLE CONTROL AND AN ACCIDENT.

Remedy: REPLACE THE C SHAPED CLUTCH RELEASE LEVER.

Reported: 1989-12-22 (December 22, 1989) · Model years: 1987, 1988, 1989

THROTTLE RETURN SPRINGS MAY FAIL DURING NORMAL OPERATION WITHOUT PRIOR WARNING.

Consequence: IF BOTH THROTTLE RETURN SPRINGS FAIL THE ENGINE THROTTLENAT NOT RETURN TO THE IDLE POSTION WHEN THE THROTTLE PEDAL IS RELEASED. THIS MAYRESULT IN LOSS OF VEHICLE CONTROL, AND COULD CAUSE AN ACCIDENT.

Remedy: MANUFACTURER WILL REPLACE THE THROTTLE RETURN SPRINGS.

Reported: 1994-11-09 (November 9, 1994) · Model years: 1987, 1988, 1989, 1990, 1991, 1992

THE ALUMINUM REAR SPRING SHACKLE BRACKETS HAVE DEVELOPED CRACKS WHICH CAN LEAD TO SEPARATION OF THE BRACKETS FROM THE FRAME RAIL.

Consequence: THE SUSPENSION CAN DROP DOWN ON ONE SIDE, CAUSING A REDUCTION OF STEERING CONTROL WHICH COULD RESULT IN AN ACCIDENT.

Remedy: DEALERS WILL REPLACE THE SPRING BRACKETS.

Reported: 1995-02-22 (February 22, 1995) · Model years: 1987, 1988, 1989, 1990

THE BRAKE RETURN SPRINGS ON THE FRONT BRAKES CAN CONTACT THE FRONT HUBS AS THE BRAKE PADS AND DRUMS WEAR, RESULTING IN SPRING FAILURE. A PIECE OF THE FAILED SPRING CAN LODGE IN THE BRAKE CAM CAUSING THE BRAKE TO DRAG AND THE STEERING TO PULL TO ONE SIDE.

Consequence: STEERING PULL FROM THE DRAGGING BRAKE CAN INCREASE THE POTENTIAL FOR A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE FRONT HUBS ON THE AFFECTED VEHICLES.

Reported: 1990-12-06 (December 6, 1990) · Model years: 1988, 1989, 1990

WHEN BRAKE AIR LINES AND BATTERY ELECTRICAL CABLES ARE ROUTED THROUGH THE ANGLE BRACKETS ON THE FRAME RAILS, THE LEAF SPRING MAY RUB AGAINST THE BATTERY CABLES OR AIR LINES, CAUSING FRAYING AND EVENTUALLY RUPTURE.

Consequence: IF THE BATTERY CABLES ARE SUFFICIENTLY FRAYED, THE CABLESMAY CAUSE A SHORT CIRCUIT AND RESULT IN A FIRE. IF THE BRAKE AIR LINES ARERUPTURED OR PUNCTURED, SEVERELY DECREASED BRAKING ABILITY MAY ENSUE.

Remedy: REROUTE BATTERY AND AIR LINE HOSES AWAY FROM THE REAR TRANSMISSION SUPPORT SPRING.

Reported: 1996-01-05 (January 5, 1996) · Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995

THESE HEAVY TRUCKS WERE EQUIPPED WITH EXHAUST MUFFLERS WITHOUT HEAT SHIELDING.

Consequence: SOMEONE WORKING BEHIND THE CAB COULD CONTACT THE HOT MUFFLER CAUSING PERSONAL INJURY. ALSO SOME OF THESE VEHICLES WERE EQUIPPED WITH DECK PLATES WITH NO GRAB HANDLES FOR ACCESS.

Remedy: DEALERS WILL INSTALL MUFFLER SHIELDS AND, WHERE NECESSARY, GRAB HANDLES.

Reported: 1989-10-04 (October 4, 1989) · Model years: 1989

SEAT BELTS DESIGNED FOR USE ON DRIVER'S SEATS WERE INSTALLED ON PASSENGER SEATS; THIS CAUSES THE STRAP CONNECTING THE BUCKLE TO THE FLOOR TO BE TWISTED.

Consequence: STRESSES WITHIN THE BUCKLE RESULT IN FAILURE TO COMPLYWITH FMVSS 210.

Remedy: REPLACE SEAT BELT ASSEMBLIES.

Reported: 1995-01-01 (January 1, 1995) · Model years: 1990, 1991, 1992, 1993, 1994, 1995

STRAPS HOLDING THE SLEEPER UPPER BUNK IN THE RAISED POSITION CAN RELEASE WITHOUT WARNING.

Consequence: IF THE RESTRAINING STRAP RELEASES SUDDENLY, THEBUNK FALLS WITHOUT WARNING AND CAN STRIKE AN OCCUPANT SITTING IN THE LOWER BUNK CAUSING PERSONAL INJURY.

Remedy: DEALERS WILL REPLACE THE UPPER BUNK RETAINING STRAPS WITH AN IMPROVED AUTOMOTIVE SAFETY BELT STYLE DESIGN STRAP.

Reported: 1993-07-13 (July 13, 1993) · Model years: 1991, 1992

THE BURN RATE FOR THE MATTRESS TICKING EXCEEDS THE 4 INCHES PER MINUTE REQUIREMENT OF FMVSS 302, "FLAMMABILITY OF INTERIOR MATERIALS."

Consequence: EXCESSIVE BURN RATES OF INTERIOR MATERIALS PRESENTS ANINCREASED RISK OF INJURY TO VEHICLE OCCUPANTS IN CASE OF A FIRE.

Remedy: REPLACE THE MATTRESS TICKING WITH NEW COVERS THAT COMPLY WITH THE STANDARD.

Reported: 1994-12-20 (December 20, 1994) · Model years: 1994

THE ECM GROUND TERMINALS WERE INSTALLED SUCH THAT THERE IS RESIDUAL STRESS ON THE TERMINAL CAUSING THE TERMINAL TO FATIGUE AND EVENTUALLY FAIL.

Consequence: IF THIS TERMINAL FAILS, THE ENGINE WILL STOP ANDNOT RE-START. THIS CAN CAUSE LOSS OF POWER STEERING ASSIST IF THEVEHICLE IS BEING DRIVEN.

Remedy: DEALERS WILL MODIFY THE ECM GROUND TERMINAL INSTALLATION.

Reported: 1995-02-07 (February 7, 1995) · Model years: 1994

A PROTECTIVE GREASE COATING USED ON THE STEERING KNUCKLE WAS NOT REMOVED PRIOR TO ASSEMBLY OF THE STEERING ARMS. ALSO THE JOINTS COULD HAVE BEEN ASSEMBLED WITH KEYS THAT WERE SOFTER THAN SPECIFIED AND WITH NUTS OF A "SOFTER" MATERIAL THAN ANTICIPATED.

Consequence: THESE CONDITIONS CAN ALLOW THE STEERING ARM TO TURNINSIDE THE KNUCKLE SHEARING THE LOCATOR KEY RESULTING IN LOSS OF STEERING CONTROL AND INCREASING THE POTENTIAL FOR AN ACCIDENT.

Remedy: DEALERS WILL CLEAN THE STEERING ARM/KNUCKLE JOINTS, REPLACE THE NUTS AND KEYS, AND RETORQUE THE STEERING ARM NUTS.

Reported: 1996-02-06 (February 6, 1996) · Model years: 1995

THE THROTTLE RETURN SPRINGS CAN FAIL.

Consequence: IF BOTH SPRINGS FAIL, THE ENGINE IS NOT LIKELY TO RETURN TO IDLE WHEN THE ACCELERATOR IS RELEASED, CAUSING LOSS OF VEHICLE SPEED CONTROL AND SUDDENLY INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

Remedy: REPLACEMENT THROTTLE RETURN SPRINGS WILL BE MAILED DIRECTLY TO OWNERS. IF THE OWNERS PREFER, THEIR DEALERS CAN INSTALL THE SPRINGS FOR THEM.

Reported: 1996-08-01 (August 1, 1996) · Model years: 1995, 1996

THE EQUALIZING BEAM SHAFT OF THE TANDEM AXLE SUSPENSION WERE MANUFACTURED FROM AS-ROLLED SAE4140 STEEL RATHER THAN THE SPECIFIED ANNEALED SAE4140. THESE SHAFTS CAN FRACTURE INSIDE THE BEAM AT THE TOE OF THE WELD.

Consequence: VEHICLES ARE SUBJECT TO VEHICLE TILT AND POSSIBLE ROLLOVER IN THE EVENT THAT BOTH EQUALIZING BEAMS, ON THE SAME SIDE OF THE VEHICLE, EXPERIENCE A SIMULTANEOUS SHAFT FAILURE. AFFECTED SUSPENSIONS CAN ALSO DROP AND CONTACT THE ROAD SURFACE GENERATING SPARKS WHICH COULD IGNITE FLAMMABLE MATERIAL.

Remedy: OWNER NOTIFICATION IS BEING CONDUCTED BY NEWAY ANCHORLOK. DEALERS WILL INSPECT AND REPLACE ALL SUSPENSION SUSPENSION BEAMS WITH SUSPENSION BEAMS CONTAINING APPROPRIATE SHAFTS.

Reported: 1996-03-27 (March 27, 1996) · Model years: 1996

THESE TRUCKS WERE NOT BUILT WITH INVERSION VALVES DUE TO A PROGRAMMING ERROR. THE INVERSION VALVE PROVIDES MODULATED SPRING BRAKE APPLICATION DURING EMERGENCY BRAKING WHEN THE "A" PORTION OF THE AIR BRAKE SYSTEM HAS FAILED.

Consequence: IN AN EMERGENCY SITUATION, THE BRAKE SYSTEM WOULD NOT WORK PROPERLY INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

Remedy: DEALERS WILL INSTALL AN INVERSION VALVE IN THESE VEHICLES.

Reported: 1996-06-17 (June 17, 1996) · Model years: 1996

THE WINDSHIELD WIPER ARM CAN INTERFERE WITH THE MAIN CAB DASH HARNESS WHICH PASSES BEHIND THE CENTER DASH SECTION. THE WIPER ARM CAN WEAR THROUGH ONE OR MORE OF THE WIRES IN THE HARNESS AND CAUSE A SHORT CIRCUIT.

Consequence: IN ELECTRONIC ENGINES (CATERPILLAR ONLY) OR DDA ENGINES, THE ENGINE WOULD STOP. IF THE ENGINE WERE TO STOP SUDDENLY WHEN THE VEHICLE WAS TRAVELING AT A HIGH RATE OF SPEED AND MANEUVERING THROUGH TRAFFIC, THERE WOULD BE A POTENTIAL FOR A VEHICLE ACCIDENT.

Remedy: DEALERS WILL MODIFY THE MAIN CAB WIRING HARNESS ROUTING.