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NHTSA vehicle safety data

2004 Kenworth T800 Recalls & Complaints

The 2004 Kenworth T800 has 12 NHTSA recall campaigns and 3 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Kenworth dealer.

NHTSA recall and complaint data for the 2004 Kenworth T800. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Kenworth T800 owner complaints

Owners have filed 3 complaints with NHTSA about the 2004 Kenworth T800, describing incidents dated April 20, 2005 to April 19, 2011.

Most-cited components

  • Electrical System 1 complaint
  • Unknown or Other 1 complaint
  • Vehicle Speed Control 1 complaint

Of the 3 complaints on file, 1 reports a crash and 2 a fire; across all 3 complaints, owners report 1 injury (owner-reported, not verified by NHTSA).

Newest complaints

  • ODI #10404975 · Filed

    2004 KENWORTH T800, UNIT 1 WAS TRAVELING EAST ON THE OHIO TURNPIKE ON THE RIGHT SHOULDER IN THE CONSTRUCTION ZONE. UNIT 1 STATED SHE SMELLED SMOKE COMING FROM UNDERNEATH THE GLOVE BOX AREA. UNIT 1 STOPPED AND GOT OUT OF THE VEHICLE. UNIT 1 BECAME ENGULFED AND WAS PUT OUT BY WATER TRUCK IN THE…

  • ODI #10398226 · Filed

    TL*THE CONTACT OWNS A 2004 KENWORTH T800B TRUCK. THE CONTACT STATED THE GEAR WAS IN THE PARK POSITION WITH THE ENGINE IN OPERATION WHEN SHE EXITED THE VEHICLE. THE CONTACT NOTICED FLAMES EMITTING FROM THE INSTRUMENT PANEL UPON ENTERING THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES. THE…

  • ODI #10118239 · Filed

    SUDDEN FULL UNCONTROLLED ACCELERATION BROUGHT ON BY A REAR END COLLISION WHILE MY VEHICLE WAS STOPPED IN TRAFFIC. DUMP TRUCK WITH ALLISON AUTOMATIC TRANSMISSION. TRANSMISSION TOWER BUTTONS WERE UNRESPONSIVE AND TRUCK WAS ESTIMATED BY WITNESS TO JUMP TO ALMOST IMMEDIATE 60 PLUS. DID NOT STOP UNTIL…

Read all 3 complaints

DRUM BRAKE ASSEMBLIES

NHTSA #09V239000 · Service Brakes, Air · NHTSA notice

Reported June 30, 2009 · PACCAR INCORPORATED

Potentially affected: 3,423 vehicles

Manufacturer campaign 09KW7 · Owners notified July 20, 2009

Defect description

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.

Safety consequence

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

Manufacturer remedy

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.

Notes

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> .

BRAKE ASSEMBLIES/AIRGLIDE 400 REAR SUSPENSION

NHTSA #08V485000 · Suspension · NHTSA notice

Reported September 24, 2008 · PACCAR INCORPORATED

Potentially affected: 130 vehicles

Manufacturer campaign 08KWB · Owners notified January 26, 2009 · Vehicles built July 7, 2003 – September 11, 2008 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer remedy

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.

Notes

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.

TRANSMISSION AUTO NEUTRAL FUNCTION/ALLISON

NHTSA #07V107000 · Power Train — Automatic Transmission · NHTSA notice

Reported March 16, 2007 · PACCAR INCORPORATED

Potentially affected: 4,592 vehicles

Manufacturer campaign 07KW3 · Owners notified May 9, 2007 · Vehicles built February 6, 2002 – February 26, 2007 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer remedy

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.

Notes

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.

VARIABLE VALVE ACTUATION OIL LINE/OIL LEAK

NHTSA #05V570000 · Engine and Engine Cooling · NHTSA notice

Reported December 22, 2005 · PACCAR INCORPORATED

Potentially affected: 30,995 vehicles

Manufacturer campaign 05KW7 & 1205E · Owners notified April 17, 2006 · Vehicles built April 9, 2003 – December 14, 2005 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety consequence

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

Manufacturer remedy

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.

Notes

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.

FRACTURE SUSPENSION BEAM/HOLLAND

NHTSA #05V189000 · Suspension · NHTSA notice

Reported April 28, 2005 · PACCAR INCORPORATED

Potentially affected: 1,026 vehicles

Manufacturer campaign 05KW3 & 405-B · Owners notified June 10, 2005 · Vehicles built January 1, 2004 – December 31, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer remedy

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.

Notes

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.

BURNER TUBES/WEBASTO

NHTSA #05V084000 · Engine and Engine Cooling · NHTSA notice

Reported March 4, 2005 · PACCAR INCORPORATED

Potentially affected: 39 vehicles

Manufacturer campaign 05KW1 & 305-A · Owners notified April 4, 2005 · Vehicles built November 11, 2002 – August 13, 2003 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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

Safety consequence

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

Manufacturer remedy

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.

Notes

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.

PACCAR/KENWORTH/WIRING HARNESS

NHTSA #04V580000 · Electrical System — Wiring · NHTSA notice

Reported December 10, 2004 · PACCAR INCORPORATED

Potentially affected: 4,322 vehicles

Manufacturer campaign 04KW8 · Owners notified January 13, 2005 · Vehicles built August 10, 2004 – October 19, 2004 (per NHTSA)

Defect description

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

Safety consequence

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

Manufacturer remedy

DEALERS WILL REPLACE THE HARNESS. THE RECALL BEGAN JANUARY 13, 2005. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.

Notes

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).

PACCAR/KENWORTH/CAB SUB-ASSEMBLY

NHTSA #04V533000 · Structure · NHTSA notice

Reported November 2, 2004 · PACCAR INCORPORATED

Potentially affected: 2,851 vehicles

Manufacturer campaign 04KW7 · Owners notified November 19, 2004 · Vehicles built January 2, 2004 – May 12, 2004 (per NHTSA)

Defect description

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

Safety consequence

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.

Manufacturer remedy

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.

Notes

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).

PACCAR/KENWORTH/JOINT FASTENERS

NHTSA #04V449000 · Power Train — Driveline — Universal Joint · NHTSA notice

Reported September 13, 2004 · PACCAR INCORPORATED

Potentially affected: 203 vehicles

Manufacturer campaign 04KW6 · Owners notified November 12, 2004 · Vehicles built July 12, 2004 – August 18, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer remedy

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.

Notes

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).

PACCAR/KENWORTH/WIRING

NHTSA #04V360000 · Electrical System — Wiring — Front Underhood · NHTSA notice

Reported July 21, 2004 · PACCAR INCORPORATED

Potentially affected: 15 vehicles

Manufacturer campaign 04KW3 · Owners notified August 31, 2004 · Vehicles built November 3, 2003 – June 14, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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

Manufacturer remedy

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.

Notes

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).

PACCAR/KENWORTH CERTIFICATION LABEL

NHTSA #04V356000 · Equipment — Other — Labels · NHTSA notice

Reported July 15, 2004 · PACCAR INCORPORATED

Potentially affected: 92 vehicles

Manufacturer campaign 04KW2 · Owners notified August 12, 2004 · Vehicles built June 24, 2004 – June 28, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer remedy

OWNERS WILL BE PROVIDED WITH A CORRECTED LABEL. THE RECALL BEGAN AUGUST 12, 2004. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.

Notes

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).

PACCAR/FMVSS 102/TRANSMISSION HARNESS

NHTSA #04V174000 · Electrical System — Wiring · NHTSA notice

Reported April 12, 2004 · PACCAR INCORPORATED

Potentially affected: 25 vehicles

Manufacturer campaign 04KW1 · Owners notified May 7, 2004 · Vehicles built February 5, 2003 – January 13, 2004 (per NHTSA)

Defect description

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.

Safety consequence

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.

Manufacturer remedy

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.

Notes

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).

Other Kenworth T800 model years

Check your 2004 Kenworth T800 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Kenworth T800 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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