More than 21,500 Western Star trucks are being recalled because of a risk of fire caused by an incorrectly installed battery connection.

In certain 2020-2026 Western Star 49X and 2021-2026 Western Star 47X vehicles, a stud connecting the battery to the starter at the frame rail may have been incorrectly installed, which can cause a short circuit.

• Western Star 47X model years 2021-2026, 11,981 trucks, produced July 8, 2020, through May 8, 2025.

• Western Star 49X model years 2020-2026, 9,579 trucks, produced March 19, 2019, through May 14, 2025.

The recalled trucks were configured with a positive junction point stud that connects the battery and/or auxiliary power distribution to starter at the frame rail, which may have been installed incorrectly. 

If the positive junction point stud was installed incorrectly, this can result in a short circuit, increasing the risk of a thermal event or vehicle fire.

Warning signs: Drivers may experience a slow or no crank when starting their vehicle. There may be corrosion present around the stud and/or cable lug.

Vehicles outside the recall population have different design configurations that does not have the suspect junction point stud.

How DTNA Found the Defect

Between March 2023 and March 2024, Daimler Truck North America received five reports of corrosion at the battery jump stud, and in December 2023 it was notified of a fire at the junction stud. 

An additional report of melted cables at the junction stud was received in February 2024. In early March 2024, DTNA received two reports of incorrect cable lug orientation.

Based on this, DTNA initiated an investigation, and in August 2024 concluded that a recall was not warranted at that time. The defect had a low rate of frequency, and it was possible to detect the condition during a pre- or post-trip inspection.

However, in February and March of this year, there were several additional field reports of localized fires and/or melted/burnt studs. This prompted DTNA to renew its investigation, finding that an increased number of thermal events were identified with units built at certain manufacturing facilities, ranging from melted or burnt components to isolated vehicle fires. 

Based on this information, on May 12, DTNA decided to conduct a recall to address this issue.

What DTNA Is Doing to Address The Production Problem

DTNA implemented updated production processes to prevent this problem in the future, including revised torque specifications, consistent application of dielectric paint, and additional inspection for proper orientation of the cable lug.

The company is aware of approximately 36 potentially related warranty claims and 15 potentially related field reports. There have been no reports of death or injury related to this issue.

The remedy is currently under development. The manufacturer has not yet provided a schedule for recall notification. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is F1020.