Western Star Conventional Recalls & Complaints by Model Year

NHTSA lists 18 safety recalls and 3 owner complaints across 15 model years of the Western Star Conventional (1983–1999). The most-complained-about year is 1999.

Pick your Western Star Conventional model year

• 1983
• 1984
• 1985
• 1986
• 1987
• 1988
• 1989
• 1990
• 1991
• 1992
• 1993
• 1994
• 1995
• 1996
• 1999

What Western Star Conventional owners complain about

Across all model years, owners have filed 3 complaints with NHTSA. The 1999 model year has the most, with 2.

• Power train: axle assembly1
• Power train: clutch assembly1
• Service brakes, hydraulic: antilock/traction control/electronic limited slip1
• Unknown or other1

All Western Star Conventional recalls (18)

Every NHTSA safety campaign that lists a Western Star Conventional, most recent first, with the model years each one covers.

1. Suspension

   NHTSA 96V124003 Reported August 1, 1996 36 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   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.

   Remedy: Owner notification is being conducted by neway anchorlok. Dealers will inspect and replace all suspension suspension beams with suspension beams containing appropriate shafts.

   Model years: 1995, 1996

2. Interior/under dash (electrical system)

   NHTSA 96V100000 Reported June 17, 1996 325 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   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.

   Remedy: Dealers will modify the main cab wiring harness routing.

   Model years: 1996

3. Service brakes, air

   NHTSA 96V053000 Reported March 27, 1996 12 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   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.

   Remedy: Dealers will install an inversion valve in these vehicles.

   Model years: 1996

4. Springs (vehicle speed control)

   NHTSA 96V025000 Reported February 6, 1996 490 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   The throttle return springs can fail.

   Remedy: Replacement throttle return springs will be mailed directly to owners. If the owners prefer, their dealers can install the springs for them.

   Model years: 1995

5. Manifold/header/muffler/tail pipe (engine and engine cooling)

   NHTSA 96V022000 Reported January 5, 1996 21 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   These heavy trucks were equipped with exhaust mufflers without heat shielding.

   Remedy: Dealers will install muffler shields and, where necessary, grab handles.

   Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995

6. Drum (service brakes)

   NHTSA 95V034000 Reported February 22, 1995 48 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   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.

   Remedy: Dealers will replace the front hubs on the affected vehicles.

   Model years: 1987, 1988, 1989, 1990

7. Arm (steering)

   NHTSA 95V019000 Reported February 7, 1995 159 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   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.

   Remedy: Dealers will clean the steering arm/knuckle joints, replace the nuts and keys, and retorque the steering arm nuts.

   Model years: 1994

8. Recreational vehicle/trailer (equipment)

   NHTSA 95V014000 Reported January 1, 1995 122 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   Straps holding the sleeper upper bunk in the raised position can release without warning.

   Remedy: Dealers will replace the upper bunk retaining straps with an improved automotive safety belt style design strap.

   Model years: 1990, 1991, 1992, 1993, 1994, 1995

9. Electrical system: wiring

   NHTSA 94V247000 Reported December 20, 1994 192 vehicles potentially affected WESTERN STAR TRUCKS, INC.

   The ECM ground terminals were installed such that there is residual stress on the terminal causing the terminal to fatigue and eventually fail.

   Remedy: Dealers will modify the ECM ground terminal installation.

   Model years: 1994

10. Coil springs (suspension)

    NHTSA 94V221000 Reported November 9, 1994 1,690 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    The aluminum rear spring shackle brackets have developed cracks which can lead to separation of the brackets from the frame rail.

    Remedy: Dealers will replace the spring brackets.

    Model years: 1987, 1988, 1989, 1990, 1991, 1992

11. Structure

    NHTSA 93V207000 Reported December 7, 1993 5,304 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    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.

    Remedy: Western star dealers will remove and destroy the recalled grab handles. New handles will be installed on these vehicles.

    Model years: 1986, 1987, 1988, 1989, 1990, 1991

12. Recreational vehicle/trailer (equipment)

    NHTSA 93V117000 Reported July 13, 1993 16 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    The burn rate for the mattress ticking exceeds the 4 inches per minute requirement of FMVSS 302, "flammability of interior materials."

    Remedy: Replace the mattress ticking with new covers that comply with the standard.

    Model years: 1991, 1992

13. Pedal/hand lever(motorcycle) (power train)

    NHTSA 92V143000 Reported October 8, 1992 10,893 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    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.

    Remedy: Replace the aluminum lever with an iron lever.

    Model years: 1985, 1986, 1987, 1988, 1989, 1990

14. Cables (electrical system)

    NHTSA 90V200000 Reported December 6, 1990 196 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    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.

    Remedy: Reroute battery and air line hoses away from the rear transmission support spring.

    Model years: 1988, 1989, 1990

15. Springs (vehicle speed control)

    NHTSA 89V233000 Reported December 22, 1989 75 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    Throttle return springs may fail during normal operation without prior warning.

    Remedy: Manufacturer will replace the throttle return springs.

    Model years: 1987, 1988, 1989

16. Anchorage (seat belts)

    NHTSA 89V165000 Reported October 4, 1989 7 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    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.

    Remedy: Replace seat belt assemblies.

    Model years: 1989

17. Springs (vehicle speed control)

    NHTSA 88V023000 Reported February 26, 1988 303 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    Throttle return springs may fail during normal operation without prior warning.

    Remedy: Replace throttle return springs.

    Model years: 1983, 1984, 1985, 1986, 1987, 1988

18. Pedal/hand lever(motorcycle) (power train)

    NHTSA 88V005000 Reported January 18, 1988 1,097 vehicles potentially affected WESTERN STAR TRUCKS, INC.

    The c shaped clutch release lever may have been weakened due to casting imperfections.

    Remedy: Replace the c shaped clutch release lever.

    Model years: 1987

Other Western Star models

• 490017 complaints
• 47006 complaints
• 49644 complaints
• 57004 complaints
• 47X3 complaints
• 4900EX3 complaints
• Constellation3 complaints
• Western Star3 complaints

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.