Daimler Truck North America (DTNA) is issuing an expanded recall for nearly 27,000 Western Star trucks after reports show that the previous battery repair did not fully prevent fire hazards. The recall affects Western Star 47X (2021–2027) and 49X (2020–2027) models, including trucks already repaired under last year’s campaign.
Why These Trucks Are Being Recalled
The issue involves a stud connecting the battery to the starter at the frame rail. If installed incorrectly or corroded, the stud can short circuit, potentially causing a “thermal event,” such as a fire. DTNA estimates only about 1% of the affected trucks actually have the defect, but the risk is serious enough to warrant a full recall.
Signs your truck may have this problem include a slow or no crank when starting or visible corrosion around the battery stud or cable lug.
Trucks Covered in the Recall
The recall covers:
- Certain 2021–2027 Western Star 47X trucks and 2020–2027 Western Star 49X trucks built from the start of production through February 3, 2026.
- 2026–2027 47X and 49X vehicles produced between May 14, 2025, and February 3, 2026, which were manufactured with a revised inspection process meant to fix the problem.
All affected trucks share a particular positive junction point stud that connects the battery or auxiliary power distribution to the starter at the frame rail.
Reports of Melted Frame Rails and Corrosion
DTNA first identified this defect in May 2025. Their initial remedy included adjusting stud torque, applying dielectric paint, and checking cable lug orientation. More than 17,000 trucks were repaired by January 2026.
However, early in 2026, reports surfaced of thermal events and smoke on trucks that had already received the recall fix. One New York truck had corrosion that caused an arced cable, melting the frame rail. Other vehicles showed corrosion at the junction stud even without a thermal event.
Winter Weather Makes Corrosion Worse
The failures were concentrated in “salt belt” states and parts of Canada, where winter road salts accelerate corrosion. DTNA found that even trucks manufactured after the previous fix could still experience corrosion, though no fires were reported.
This led DTNA to expand the recall on February 4, 2026, covering all vehicles affected by the prior recall and those made with the earlier revised process.
What Truck Drivers Should Know
DTNA is developing a new remedy. Owner notification letters will be mailed on April 11, 2026. Drivers should contact DTNA customer service at 1-800-547-0712 for questions. The recall number is F1029.
Vehicles already repaired under the previous recall will need the updated fix. There have been approximately 52 warranty claims and 18 field reports related to this issue from March 2023 through January 2026. No injuries or fatalities have been reported.
Source: Heavy Duty Trucking
