2005 Kenworth T800 Problems, Complaints & Recalls

Problem: 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.

Risk: Cracking can cause a complete fracture of the cam tube, which could increase stopping distance and decrease parking brake hold capability.

Fix: 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.

Problem: Paccar is recalling 140 my 2005, 2007-2009 t800, w900, and t660 trucks. The caliper mounting fasteners attaching the air disc brake caliper assembly to the torque plate may have received insufficient torque during the installation process. The insufficient torque may allow the air disc brake caliper assembly to become loose and possibly separate from the vehicle.

Risk: This could result in reduced braking capacity and also a road debris hazard, increasing the risk of a crash.

Fix: Dealers will inspect air disc brake caliper assemblies and replace the caliper mounting fasteners and torque properly. This service will be performed free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact kenworth at 1-425-828-5440.

Problem: 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.

Risk: A failure may reduce vehicle brake performance, increasing the risk of a crash.

Fix: 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.

Problem: Paccar is recalling 130 my 2005-2007 kenworth c500, t800, w900, and peterbilt models 357 and 379 tractor trailers equipped with fabco slack adjusters on sisu axles. The slack adjusters may fail as a result of a fatigue crack rendering the slack adjuster inoperative. This could reduce braking effectiveness.

Risk: Reduction in braking capacity could increase the risk of a crash.

Fix: Dealers will inspect and replace the slack adjusters free of charge. The recall began on march 21, 2008. Owners may contact kenworth at 1-425-828-5440 and peterbilt at 1-940-591-4196.

Problem: On certain trucks equipped with caterpillar c11, c13 or c15 engines, the oil fill cap can become dislodged due to cap damage or improper installation and become lodged in the u-joint of the steering driveline and steering gear.

Risk: If the cap becomes dodged in this area, it may result in difficulty steering the vehicle or cause complete steering lock-up increasing the risk of a crash.

Fix: Paccar is working with caterpillar to repair these vehicles. Revised oil cap retention based on the engine model/configuration will be incorporated to prevent steering lock-up. The recall began during december 2007. Owners may contact caterpillar at 1-800-447-4986 or kenworth at 425-828-5440.

Problem: On certain trucks, the removable tow hitch ,when used to tow or lift a vehicle, can fail due to defective material in the tow hitch.

Risk: If the tow hitch assembly fails while a vehicle is being towed or lifted, it may cause an accident that could result in personal injury or death.

Fix: Dealers will replace the tow pin assembly free of charge. The recall began on september 4, 2007. Owners may contact kenworth at 425-828-5440 or peterbilt at 940-591-4201.

Problem: 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.

Risk: 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.

Fix: 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.

Problem: 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.

Risk: The oil line may be cut on the cylinder head causing an oil leak and a possible fire.

Fix: 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.

Problem: On certain trucks equipped with the bendix electronic stability control (esp) system, the system uses multiple sensors and an electronic control unit (ecu) to control vehicle under steer, over-steer, and rollover situations. The system relies on vehicle sensors to be functioning and aligned properly. The steering angle sensor has the potential to be misaligned with the steering column shaft, thereby providing incorrect information to the bendix ecu.

Risk: This condition could affect vehicle throttle control and braking, thereby leading to loss of vehicle steering control which could cause a crash without warning.

Fix: Because of the immediate and substantial risk, kenworth and peterbilt dealers will first deactivate the yaw control feature of the bendix esp system preventing inadvertent esp activation. When parts are available, the steering column will be replaced to insure proper alignment of the steering shaft sensor and the full esp system will be reactivated. The recall began on december 7, 2005. Parts to complete the remedy are estimated to be available in early 2006. Owners may contact kenworth at 1-425-828-5440 or peterbilt at 1-940-591-4201.

Problem: On certain trucks and tractors equipped with airglide high-articulation rear suspensions, the c65-1006 sway bar used in this rear suspension may experience a reduction in fatigue life due to either a manufacturing process or a high induced stress during an extreme suspension articulation event.

Risk: Both of these conditions can lead to a failure of the sway bar which could cause the rear axle to come loose, increasing the risk of a crash.

Fix: The inspection and repair of these vehicles will depend on the type of vehicle (tractor or truck) and the intended service application. This inspection and repair criteria will be forthcoming. The recall began on june 30, 2005. Owners may contact kenworth at 1-425-828-5440.

Problem: 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.

Risk: This could cause sparks that could potentially ignite and cause a fire.

Fix: 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.

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

Risk: Should the burner tube fail, the coolant heater could overheat, possibly resulting in a fire.

Fix: 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.