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2004 Kenworth T800 Recalls, Complaints & Specs

12 safety recalls list the 2004 Kenworth T800, and owners have filed 3 complaints with NHTSA. Check your own VIN below.

12
safety recalls
3
owner complaints to NHTSA
1 / 2
complaints citing a crash / fire

12 safety recalls for the 2004 Kenworth T800

Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.

  1. Service brakes, air

    NHTSA 09V239000 Reported 3,423 vehicles potentially affected PACCAR INCORPORATED

    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…

    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…

  2. Suspension

    NHTSA 08V485000 Reported 130 vehicles potentially affected PACCAR INCORPORATED

    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…

    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…

  3. Automatic transmission (power train)

    NHTSA 07V107000 Reported 4,592 vehicles potentially affected PACCAR INCORPORATED

    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.

    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…

  4. Engine and engine cooling

    NHTSA 05V570000 Reported 30,995 vehicles potentially affected PACCAR INCORPORATED

    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.

    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…

  5. Suspension

    NHTSA 05V189000 Reported 1,026 vehicles potentially affected PACCAR INCORPORATED

    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…

    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.…

  6. Engine and engine cooling

    NHTSA 05V084000 Reported 39 vehicles potentially affected PACCAR INCORPORATED

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

    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.

  7. Electrical system: wiring

    NHTSA 04V580000 Reported 4,322 vehicles potentially affected PACCAR INCORPORATED

    On certain trucks, the power feed harness p92-1993 terminals were not properly crimped.

    Remedy: Dealers will replace the harness. The recall began january 13, 2005. Owners should contact kenworth at 1-425-828-5440.

  8. Structure

    NHTSA 04V533000 Reported 2,851 vehicles potentially affected PACCAR INCORPORATED

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

    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.

  9. Universal joint (power train)

    NHTSA 04V449000 Reported 203 vehicles potentially affected PACCAR INCORPORATED

    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.

    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.

  10. Electrical system: front underhood

    NHTSA 04V360000 Reported 15 vehicles potentially affected PACCAR INCORPORATED

    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.

    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…

  11. Labels (equipment)

    NHTSA 04V356000 Reported 92 vehicles potentially affected PACCAR INCORPORATED

    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.

    Remedy: Owners will be provided with a corrected label. The recall began august 12, 2004. Owners should contact kenworth at 1-425-828-5440.

  12. Electrical system: wiring

    NHTSA 04V174000 Reported 25 vehicles potentially affected PACCAR INCORPORATED

    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.

    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.

3 owner complaints filed with NHTSA

Owners of the 2004 Kenworth T800 have filed 3 complaints with NHTSA; 1 describe a crash and 2 describe a fire. Reports cite 1 injury and 0 deaths. The average mileage at failure in those reports is 155,000 miles. Complaints peaked in 2011 with 2 filed that year.

Most-reported components

What owners are reporting

“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 sto”

Owner complaint to NHTSA, June 2, 2011 · Unknown or other

“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”

Owner complaint to NHTSA, April 29, 2011 · Electrical system

Compare Kenworth T800 model years

Recall and complaint counts for every Kenworth T800 model year in NHTSA's database.

Model yearRecallsComplaints
1987 Kenworth T80020
1988 Kenworth T80020
1989 Kenworth T80030
1990 Kenworth T80030
1991 Kenworth T80040
1992 Kenworth T80010
1993 Kenworth T80010
1994 Kenworth T80032
1995 Kenworth T80052
1996 Kenworth T80081
1997 Kenworth T80091
1998 Kenworth T80081
1999 Kenworth T800124
2000 Kenworth T800101
2001 Kenworth T800101
2002 Kenworth T80060
2003 Kenworth T80071
2004 Kenworth T800123
2005 Kenworth T800123
2006 Kenworth T800134
2007 Kenworth T800201
2008 Kenworth T800251
2009 Kenworth T800192
2010 Kenworth T800111
2011 Kenworth T800131
2012 Kenworth T800101
2013 Kenworth T80080
2014 Kenworth T800120
2015 Kenworth T800120
2016 Kenworth T800121
2017 Kenworth T80080
2018 Kenworth T800111
2019 Kenworth T80080
2020 Kenworth T80090
2021 Kenworth T80010
2022 Kenworth T80010
2023 Kenworth T80010
2024 Kenworth T80040
2025 Kenworth T80010

Checking a specific 2004 Kenworth T800

How do I know if my 2004 Kenworth T800 has an open recall?

Enter your 17-character VIN above. The VIN is on the driver's side dashboard (visible through the windshield), the driver's door jamb sticker, and your registration or insurance card. The check runs against NHTSA's live database and tells you which campaigns list your vehicle. 12 campaigns currently list the 2004 Kenworth T800; your car may already have been repaired under some of them.

Is the recall repair free?

Yes. Under federal law, manufacturers must fix safety recalls at no charge for vehicles up to 15 years old from the date of sale to the first owner. Contact any authorised Kenworth dealer with your VIN and the NHTSA campaign number (for example 04V174000).

What is the difference between a recall and a complaint?

A recall is a safety campaign filed by the manufacturer or ordered by NHTSA, with a defined defect and remedy. A complaint is a report an owner sent to NHTSA; it is not verified, but patterns of complaints are what trigger NHTSA investigations and, eventually, recalls.

Other Kenworth models

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.