Problems owners report
Complaints filed with NHTSA about the 2005 Western Star 4900, by the system named in each complaint. One complaint can name several.
- Visibility1
- Power train1
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 0 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 9 2005 4900 vehicles were involved in crashes on US public roads in which someone died; 0 people died inside them. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2005 Western Star 4900 failed the safety check 1.16% of the time — 50% less often than the average 2005 passenger car (2.30%). Median odometer at inspection: 270,068 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Recalls in Canada
12 Transport Canada recalls for the 2005 Western Star 4900.
| 2019237 17 May 2019 | Brakes Issue: Certain trucks were built with air reservoir tanks that are too small in relation to the size of the air brake chambers. Canadian regulations require e… |
| 2017636 18 Dec 2017 | Accessories On certain vehicles equipped with Kidde fire extinguishers with black plastic handles and valves, the fire extinguishers may become clogged or require excessive… |
| 2011345 19 Sept 2011 | Fuel System On certain trucks, the plastic low-pressure fuel line between the engine-mounted fuel filter and the engine block may develop a diesel fuel leak. The location … |
| 2010201 14 Jun 2010 | Steering On certain twin-steer 4900SA vehicles, the spacer used to connect the aft steer axle idler arm to the frame rail may develop cracks and eventually break under s… |
| 2009270 22 Sept 2009 | Engine On certain vehicles equipped with a Caterpillar C15 engine, the Variable Valve Actuation (VVA) oil line may wear against the P-clip retaining the oil line. An … |
| 2008078 4 Mar 2008 | Fuel System On certain trucks, the high-pressure fuel line at each injector may fatigue and fracture if a fastener at the end of the line is not properly connected. This w… |
| 2007384 3 Dec 2007 | Brakes On certain trucks, the rear brake slack adjusters may fail, reducing brake effectiveness. Extended stopping distance could cause a crash resulting in property … |
| 2006084 19 Apr 2006 | Suspension On certain vehicles, the rear suspension transverse beam castings were not made to specifications. If a casting were to break when the vehicle is in motion, pa… |
| 2006034 9 Feb 2006 | Engine On certain vehicles equipped with a Caterpillar engine, the Variable Valve Actuation oil line (VVA line) used on 6 cylinder, 15L turbocharged and air-to-air aft… |
| 2005320 18 Oct 2005 | Fuel System On certain vehicles fitted with optional in-cab batteries, fuel lines may contact the cab power harness, resulting in chafe damage that could present a fire haz… |
| 2005266 14 Sept 2005 | Steering On certain vehicles, the front hubs may fracture and allow the wheel assembly to separate from the vehicle. This could cause a crash without prior warning. Co… |
| 2005140 10 Jun 2005 | Wheels On certain vehicles, wheels were not pre-stressed and could, over time, develop cracks. If allowed to propagate, the cracks may result in wheel failure, which … |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
Daimler Trucks North America LLC (DTNA) is recalling certain 2002-2017 Freightliner Cascadia, Century Class, Columbia and Coronado trucks and Western Star 4700, 4900, 5700, 5900 and 6900 trucks. These vehicles are equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers that may become clogged, preventing the extinguisher from discharging as expected or excessive force may be needed to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf
DAIMLER TRUCKS IS RECALLING CERTAIN MODEL YEAR 2004 THROUGH 2008 HEAVY TRUCKS MANUFACTURED FROM JULY 11, 2003, THROUGH SEPTEMBER 28, 2007, EQUIPPED WITH EPA04 MODEL MBE4000 ENGINES BUILT WITH PLASTIC LOW PRESSURE FUEL LINES AND FUEL FILTERS MOUNTED NEAR THE CENTER OF THE ENGINE ON THE LEFT-HAND SIDE. THE PLASTIC LOW PRESSURE FUEL LINE BETWEEN ENGINE MOUNTED FUEL FILTER AND ENGINE BLOCK MAY DEVELOP A SUBSTANTIAL DIESEL FUEL LEAK.
DAIMLER TRUCKS IS RECALLING MODEL YEAR 2004-2010 TRUCKS EQUIPPED WITH CATERPILLAR C15 ENGINE. THE VARIABLE VALVE ACTUATION OIL LINE MAY RUB AGAINST THE P-CLIPS RETAINING THE OIL LINE, CAUSING AN OIL LEAK.
DAIMLER TRUCKS IS RECALLING 62,000 MY 2005-2007 FREIGHTLINER BUSINESS CLASS, CENTURY CLASS, COLUMBIA, CORONADO, FLD, CLASSIC, STERLING A-LINE, L-LINE, AND WESTERN STAR 4900 TRUCKS. A FRACTURED FUEL LINE COULD LEAK DIESEL FUEL.
ON CERTAIN HEAVY DUTY TRUCKS BUILT WITH SISU FR2P-21, SISU FR2P-26, SISU FR3P-33, OR SISU FR3P-48 REAR AXLES, A COUNTER-BORE MACHINED IN BOTH ENDS OF THE WORM WHEEL OPENING OF THE SLACK ADJUSTER HOUSING REDUCES MATERIAL THICKNESS BETWEEN THE WORM WHEEL OPENING AND THE WORM SHAFT OPENING. UNDER NORMAL SERVICE A CRACK MAY DEVELOP IN THIS AREA RENDERING THE SLACK ADJUSTER INOPERABLE AND REDUCING BRAKE EFFECTIVENESS.
ON CERTAIN TRUCKS 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.
ON CERTAIN TRUCKS FITTED WITH OPTIONAL IN-CAB BATTERIES, THE DUAL SUCTION/RETURN LINES MAY CONTACT THE CAB POWER HARNESS RESULTING IN CHAFING THROUGH.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Western Star told its dealers about the 2005 Western Star 4900: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10195575 | Service Solution SS 1033094 KUS Float Tube Fuel Level Sensor Inform... |
| 10184788 | Western Star Service Bulletin for Axle Flange Gasket Replaced with O-Ring. Daimler Trucks North America has released a new axle shaft to hub rubber O-ring (part number 11-30728-000) as a replacement for the paper gasket (part number 11-14418-000). The new O-ring will provide better sealing and is reusable. It is quicker and easier to use compared to the paper gasket, because using a paper gasket requires cleaning the hub when the axle shaft is removed. |
| 10170603 | Technical Service Letter for DDC Series 60 engines concerning Series 60 Cylinder Head Resurfacing/Finish. Detroit Diesel does not recommend third party resurfacing of Series 60 cylinder heads (outside of Detroit and Detroit Reman). |
| 10170323 | Service Solution for Western Star vehicles equipped with Hendrickson AIRTEK Axles experiencing a Harsh Ride. |
| 10163575 | Service Bulletin provided to customers regarding installation of a new MCM 21-pin jumper harness. |
| 10158111 | Service Bulletin Vibration and Harsh Ride Troubleshooting |
| 10158025 | Technical Publications Ordering |
| 10158021 | Fuel Level Sending Unit Retrofit |
| 10151512 | Operating Hours for the Customer Assistance Center |
| 10146308 | With the start of production on March 6, 2018, the fasteners used to attach the slide- and plate-mount style fifth wheels to the outboard angles changed to M16 metric bolts, nuts, and washers. |
| 10146307 | In some operating conditions, water may leak into the cab onto the passenger floor through the HVAC fresh air intake on the frontwall on 47,00,4900, and 5700 models. |
| 10146306 | If a GVWR certification label is lost or damaged, Freightliner will supply a duplicate label. Log on to DTNAConnect.com and under "DTNAConnect Resources", select the "Tool and Services" plus sign. Select "Request for Certification Labl or OWI." Fillout the form, then select "Review." |
| 10142301 | sbw2018 Western Star 4800 and 4900 Radiator Mounting |
| 10142277 | 33-4- Bearing Spacer Replacement, ConMet PreSet Steer Hubs |
| 10142276 | 35-11 - Bearing Spacer Replacement, ConMet PreSet Drive Hubs |
| 10142079 | sbw0001Validity List Western Star |
| 10142030 | 608-13 High Pressure Fuel Flange-Two-Filter System |
| 10142025 | RX Module Fault Codes |
| 10142015 | 707-13 Description and Operation of the HC Doser Fuel Supply Pressure Control Valve - Two Filter System |
| 10142014 | 710-13 Metal in the Fuel System - Three-Filter Fuel System |
| 10142013 | 712-13 Fuel Cooler Leak Test Procedure - Three-Filter Fuel System |
| 10142012 | 705-13 Test-E Three-Filter Fuel System |
| 10142011 | 702-13 Test E Two-Filter Fuel System |
| 10142010 | 711-13 SPN 100-FMI 4 - ALL YEARS |
| 10142000 | 717-13 Oil Pan |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Daimler Trucks North America Recalls
NHTSA Office of Defects Investigation