NHTSA vehicle safety data
2004 Western Star 4900EX Recalls, Ratings & Complaints
The 2004 Western Star 4900EX has 2 NHTSA recall campaigns and 0 owner complaints on file as of October 16, 2026. Recall repairs are usually free at an authorized Western Star dealer.
NHTSA recall and complaint data for the 2004 Western Star 4900EX. Recall data is refreshed daily from NHTSA.
POWER TRAIN:DRIVELINE
NHTSA #04V590000Reported December 15, 2004 · FREIGHTLINER LLC
Potentially affected: 1,095 vehicles
Defect description
ON CERTAIN VEHICLES, THERE IS A DEFECT IN THE INTERAXLE DRIVELINE YOKES. THE BOLT HOLES LOCATED ON THE EARWORK OF THE MALE SHAFT YOKES WERE MANUFACTURED WITH AN OVERSIZED MINOR THREAD DIAMETER.
Safety consequence
THIS CONDITION ALLOWS THE BOLTS USED IN THE HOLES TO BECOME DETACHED WHICH COULD RESULT IN A DRIVELINE SEPARATION. DRIVELINE SEPARATION COULD RESULT IN A VEHICLE CRASH.
Manufacturer remedy
DEALERS WILL REPLACE THE SUSPECT MALE SHAFT YOKES. THE RECALL BEGAN ON APRIL 4, 2005. OWNERS SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.
Notes
FREIGHTLINER RECALL NO. FL-436.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION?S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
STEERING:LINKAGES:DRAG:POWER ASSIST SYSTEM
NHTSA #04V120000Reported March 8, 2004 · FREIGHTLINER LLC
Potentially affected: 275 vehicles
Defect description
ON CERTAIN TRUCKS AND TRUCK-TRACTORS EQUIPPED WITH TRW DRAG LINK ASSEMBLIES, THE REPLACEMENT CLAMP AND DRAG LINK ASSEMBLIES CONTAIN A POTENTIALLY DEFECTIVE 5/8-11-GRADE B PREVAILING TORQUE HEX NUT. IF THE FINAL TIGHTENING IS LESS THAN 65 LB.-FT., THE CLAMP LOAD WOULD BE UNACCEPTABLY LOW AND COULD COMPROMISE THE INTEGRITY OF THE DRAG LINK.
Safety consequence
THIS COULD RESULT IN THE BALL SOCKET SEPARATING AND CAUSE LOSS OF STEERING CONTROL, INCREASING THE RISK OF PERSONAL INJURY OR A CRASH.
Manufacturer remedy
DEALERS WILL REPLACE THE AFFECTED HEX NUT(S). OWNER NOTIFICATION BEGAN ON MAY 21, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.
Notes
FREIGHTLINER RECALL NO. FL422.CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Other Western Star 4900EX model years
Check your 2004 Western Star 4900EX VIN
Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Western Star 4900EX at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.
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