2004 Kenworth W900 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 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: 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 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.

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

Risk: This could lead to intermittent power loss affecting the electrical system and possibly result in a fire.

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

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

Risk: If the huck bolts are not properly installed, in an extreme loading condition (such as frontal and/or side impact or a vehicle rollover situation), the cab structure could be compromised and not provide adequate protection for the occupant increasing the risk of personal injury.

Fix: 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.

Problem: 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.

Risk: If the u-joints were to become loose, a portion of the driveline could become detached from the vehicle and fall out from under the vehicle, which could cause a crash.

Fix: 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.

Problem: 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.

Risk: This could lead to an electrical short or arc situation which could result in an engine fire.

Fix: 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 kenworth at 1-425-828-5440.

Problem: 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.

Risk: If the tire is operated in an under-inflated condition, the load carrying capacity of the vehicle may be compromised, increasing the risk of a crash.

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

Problem: 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.

Risk: This could cause the neutral start feature of the transmission to disable allowing the vehicle to start in gear increasing the potential for a crash.

Fix: 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.