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NHTSA vehicle safety data

2005 Western Star 4900 Recalls & Complaints

The 2005 Western Star 4900 has 7 NHTSA recall campaigns and 2 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Western Star dealer.

NHTSA recall and complaint data for the 2005 Western Star 4900. Recall data is refreshed daily from NHTSA.

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

2005 Western Star 4900 owner complaints

Owners have filed 2 complaints with NHTSA about the 2005 Western Star 4900, describing incidents dated February 17, 2006 to June 21, 2006.

Most-cited components

  • Power Train 1 complaint
  • Visibility/Wiper 1 complaint

Newest complaints

  • ODI #10160779 · Filed

    PASSENGER SIDE STEER AXLE HUB FAILED. IT CRACKED IN A CIRCULAR PATTERN BETWEEN THE SPINDLE WHEEL STUDS AND THE BEARING FLANGE 360 DEGREES. *JB

  • ODI #10151196 · Filed

    AIR CONDITIONING CONDENSER AND A/C HOSE HARNES WITH BRACKET ARE FAILING. IN WARM RAINY WEATHER THERE IS A HAZARD AS DEFOGGING OF WINDSHIELD IS MINIMAL. FIRST OF 4 INCIDENTS OCCURRED SEPTEMBER 25,2005.

Read all 2 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2005 Western Star 4900 in 1 investigation. Audit Queries and Equipment Queries are administrative investigations: they look at whether companies complied with federal vehicle safety requirements, such as reporting, recall and certification rules, not at a possible vehicle defect. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Open and recently closed NHTSA defect investigations

Fire Extinguisher May Be Clogged or Inoperable

NHTSA #17V810000 · Equipment · NHTSA notice

Reported December 15, 2017 · Daimler Trucks North America LLC

Potentially affected: 24,860 vehicles

Repair completion: 0.92% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign FL-759 · Owners notified April 11, 2018 · Vehicles built July 11, 2001 – August 19, 2016 (per NHTSA)

Defect description

Daimler Trucks North America LLC (DTNA) is recalling certain 2002-2017 Freightliner Cascadia, Century Class, Columbia and Coronado trucks and Western Star 4700, 4900, 5700, 5900 and 6900 trucks. These vehicles are equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers that may become clogged, preventing the extinguisher from discharging as expected or excessive force may be needed to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf

Safety consequence

In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.

Manufacturer remedy

DTNA will notify owners, and instruct them to contact Kidde for a replacement fire extinguisher, free of charge. The recall began on April 11, 2018. Owners may contact DTNA customer service at 1-800-547-0712, or contact Kidde customer service toll-free at 1-855-262-3540, or online at www.kidde.com and click on "Product Safety Recall" for more information. DTNA's number for this recall is FL-759.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

DIESEL FUEL LEAK/DETROIT DIESEL

NHTSA #11V478000 · Fuel System, Diesel · NHTSA notice

Reported September 16, 2011 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 73,500 vehicles

Manufacturer campaign 11C-2 · Owners notified February 21, 2012 · Vehicles built starting July 11, 2003 (per NHTSA)

Defect description

DAIMLER TRUCKS IS RECALLING CERTAIN MODEL YEAR 2004 THROUGH 2008 HEAVY TRUCKS MANUFACTURED FROM JULY 11, 2003, THROUGH SEPTEMBER 28, 2007, EQUIPPED WITH EPA04 MODEL MBE4000 ENGINES BUILT WITH PLASTIC LOW PRESSURE FUEL LINES AND FUEL FILTERS MOUNTED NEAR THE CENTER OF THE ENGINE ON THE LEFT-HAND SIDE. THE PLASTIC LOW PRESSURE FUEL LINE BETWEEN ENGINE MOUNTED FUEL FILTER AND ENGINE BLOCK MAY DEVELOP A SUBSTANTIAL DIESEL FUEL LEAK.

Safety consequence

THIS COULD CREATE A ROAD HAZARD INCREASING THE RISK OF A CRASH. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Manufacturer remedy

DAIMLER TRUCKS WILL NOTIFY OWNERS AND THE REMEDY WILL BE PERFORMED BY DETROIT DIESEL CORPORATION AUTHORIZED REPAIR FACILITIES. VEHICLES WILL BE INSPECTED AND THE PLASTIC LOW PRESSURE FUEL LINE WILL BE REPLACED WITH A STEEL LOW PRESSURE FUEL LINE. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. AN INTERIM LETTER WAS MAILED TO OWNERS ON OCTOBER 28, 2011. THE SAFETY RECALL BEGAN ON FEBRUARY 21, 2012. OWNERS MAY CONTACT DAIMLER TRUCKS AT 1-800-547-0712.

Notes

DAIMLER TRUCKS' CAMPAIGN NUMBER IS 11C-2.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> .

VARIABLE VALVE ACTUATION OIL LINE/CATERPILLAR

NHTSA #09V366000 · Engine and Engine Cooling · NHTSA notice

Reported September 23, 2009 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 25,362 vehicles

Manufacturer campaign FL-558 · Owners notified May 5, 2009 · Vehicles built April 1, 2003 – June 30, 2009 (per NHTSA)

Defect description

DAIMLER TRUCKS IS RECALLING MODEL YEAR 2004-2010 TRUCKS EQUIPPED WITH CATERPILLAR C15 ENGINE. THE VARIABLE VALVE ACTUATION OIL LINE MAY RUB AGAINST THE P-CLIPS RETAINING THE OIL LINE, CAUSING AN OIL LEAK.

Safety consequence

AN OIL LEAK MAY RESULT IN A FIRE.

Manufacturer remedy

DAIMLER TRUCKS IS WORKING WITH CATERPILLAR TO REMEDY THESE VEHICLES. PLEASE SEE CATERPILLAR'S DEFECT REPORT 09E-020. CATERPILLAR WILL INSPECT AND REPAIR THE NECESSARY COMPONENTS FREE OF CHARGE. THE RECALL BEGAN ON MAY 5, 2009. OWNERS MAY CONTACT CATERPILLAR TOLL-FREE AT 1-800-447-4986 OR DAIMLER TRUCKS AT 1-800-547-0712.

Notes

DAIMLER TRUCKS RECALL NO. FL-558. 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> .

HIGH PRESSURE FUEL LINES

NHTSA #08V113000 · Fuel System, Diesel · NHTSA notice

Reported March 11, 2008 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 62,000 vehicles

Manufacturer campaign FL-526 · Owners notified July 9, 2008 · Vehicles built April 1, 2004 – April 30, 2007 (per NHTSA)

Defect description

DAIMLER TRUCKS IS RECALLING 62,000 MY 2005-2007 FREIGHTLINER BUSINESS CLASS, CENTURY CLASS, COLUMBIA, CORONADO, FLD, CLASSIC, STERLING A-LINE, L-LINE, AND WESTERN STAR 4900 TRUCKS. A FRACTURED FUEL LINE COULD LEAK DIESEL FUEL.

Safety consequence

IF A LEAK CONTINUES UNDETECTED UNDER CERTAIN CONDITIONS, FUEL MAY IGNITE AT A HOT ENGINE SURFACE AND/OR FUEL MAY BE SPILLED ON THE ROAD SURFACE.

Manufacturer remedy

HIGH PRESSURE FUEL LINES AND TRANSFER TUBES WILL BE INSPECTED AND REPLACED FREE OF CHARGED. THE RECALL BEGAN ON JULY 9, 2008. OWNERS MAY CONTACT DAIMLER TRUCKS AT 1-800-547-0712.

Notes

DAIMLER TRUCK RECALL NO. FL-526.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.

REAR SLACK ADJUSTER CRACKING

NHTSA #07V571000 · Service Brakes, Air — Slack Adjusters · NHTSA notice

Reported December 18, 2007 · FREIGHTLINER LLC

Potentially affected: 31 vehicles

Manufacturer campaign FL-518 · Owners notified July 31, 2008 · Vehicles built January 1, 2005 – January 31, 2007 (per NHTSA)

Defect description

ON CERTAIN HEAVY DUTY TRUCKS BUILT WITH SISU FR2P-21, SISU FR2P-26, SISU FR3P-33, OR SISU FR3P-48 REAR AXLES, A COUNTER-BORE MACHINED IN BOTH ENDS OF THE WORM WHEEL OPENING OF THE SLACK ADJUSTER HOUSING REDUCES MATERIAL THICKNESS BETWEEN THE WORM WHEEL OPENING AND THE WORM SHAFT OPENING. UNDER NORMAL SERVICE A CRACK MAY DEVELOP IN THIS AREA RENDERING THE SLACK ADJUSTER INOPERABLE AND REDUCING BRAKE EFFECTIVENESS.

Safety consequence

REDUCED VEHICLE BRAKING COULD LEAD TO A CRASH.

Manufacturer remedy

DEALERS WILL INSPECT THE SLACK ADJUSTERS, AND REPLACE THE ADJUSTER IF FOUND DEFECTIVE. THE RECALL BEGAN ON JULY 31, 2008. OWNERS MAY CONTACT FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-518.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.

VARIABLE VALVE ACTUATION OIL LINE/OIL LEAK

NHTSA #06V030000 · Engine and Engine Cooling · NHTSA notice

Reported February 8, 2006 · FREIGHTLINER LLC

Potentially affected: 5,771 vehicles

Manufacturer campaign FL-471 · Owners notified April 17, 2006 · Vehicles built April 9, 2004 – October 7, 2005 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

ON CERTAIN TRUCKS 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 FREIGHTLINER, WILL BE CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN FREE OF CHARGE. OWNERS MAY CALL CATERPILLAR AT 309-675-6496, OR FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-471.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.

FUEL LINE ROUTING

NHTSA #05V453000 · Fuel System, Gasoline — Delivery — Hoses, Lines/Piping, and Fittings · NHTSA notice

Reported October 5, 2005 · FREIGHTLINER LLC

Potentially affected: 600 vehicles

Manufacturer campaign FL-462 · Owners notified January 26, 2006 · Vehicles built August 9, 2001 – June 2, 2005 (per NHTSA)

Defect description

ON CERTAIN TRUCKS FITTED WITH OPTIONAL IN-CAB BATTERIES, THE DUAL SUCTION/RETURN LINES MAY CONTACT THE CAB POWER HARNESS RESULTING IN CHAFING THROUGH.

Safety consequence

THIS COULD RESULT IN A FIRE.

Manufacturer remedy

DEALERS WILL REROUTE AND SECURE THE FUEL LINES. THE RECALL BEGAN ON JANUARY 26, 2006. OWNERS MAY CONTACT FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-462.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.

Other Western Star 4900 model years

Check your 2005 Western Star 4900 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Western Star 4900 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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