Western Star is issuing a major safety recall impacting over 21,000 of its 49X and 47X trucks due to a battery-related defect that could lead to fires.
According to documents from the National Highway Traffic Safety Administration (NHTSA), the issue arises from a potential short circuit involving the battery-to-starter connection. The problem specifically affects 49X models built between 2020 and 2026, and 47X models from 2021 to 2026. A is installed stud on the frame rail, which links the battery to the starter, could result in a short — increasing the chances of an electrical fire.
Of the more than 21,500 vehicles under the recall, the breakdown includes approximately 9,500 units of the 49X and nearly 12,000 of the 47X. Despite the size of the recall population, Western Star believes the actual defect affects about 1% of those trucks.
Drivers may spot early warning signs of the problem. This could include difficulty starting the vehicle — either a slow crank or no crank at all — along with visible corrosion around the battery cable lug or stud.
As of May 29, 2025, Western Star had not yet issued a fix for the defect, and no formal notification schedule for owners has been released.
Investigation into the issue ramped up after a series of incidents. Between March 2023 and March 2024, the manufacturer received five complaints about battery corrosion. One report of a fire was submitted in December 2023, followed by a melted cable incident in February 2024. Two more similar reports came in March 2024.
Back in August 2024, Western Star assessed the situation and concluded that “a field action was not warranted at that time due to a low rate of frequency in conjunction with sufficient detectability of the condition, including during a pre- or post-trip inspection.” However, after receiving more complaints involving melted studs and fires earlier in 2025, Daimler Truck North America reopened the investigation.
From March 2023 to March 2025, Western Star recorded 36 warranty claims and 15 field reports that may be linked to this battery defect. Fortunately, no injuries or fatalities have been reported.
If you own one of the affected trucks and need more information, contact Daimler Truck North America customer service at 800-547-0712 and reference recall number F1020. For those checking through NHTSA, this recall is listed under case number 25V326.
Source: Land Line
Image Source: Truck Driver News
