1990 Western Star CONVENTIONAL: complaints, problems and recalls

Reported: 1990-12-06 (December 6, 1990)

WHEN BRAKE AIR LINES AND BATTERY ELECTRICAL CABLES ARE ROUTED THROUGH THE ANGLE BRACKETS ON THE FRAME RAILS, THE LEAF SPRING MAY RUB AGAINST THE BATTERY CABLES OR AIR LINES, CAUSING FRAYING AND EVENTUALLY RUPTURE.

Consequence: IF THE BATTERY CABLES ARE SUFFICIENTLY FRAYED, THE CABLESMAY CAUSE A SHORT CIRCUIT AND RESULT IN A FIRE. IF THE BRAKE AIR LINES ARERUPTURED OR PUNCTURED, SEVERELY DECREASED BRAKING ABILITY MAY ENSUE.

Remedy: REROUTE BATTERY AND AIR LINE HOSES AWAY FROM THE REAR TRANSMISSION SUPPORT SPRING.

Reported: 1992-10-08 (October 8, 1992)

PREMATURE FAILURE OF THE ALUMINUM CLUTCH RELEASE LEVER CAN OCCUR FROM STRESS CORROSION DUE TO CONTINUOUS LOADING OF THE LEVER AND EXPOSURE TO ROAD SALT SPRAY.

Consequence: IF THE FAILURE OCCURS DURING VEHICLE OPERATION, THECLUTCH IS RENDERED INOPERATIVE AND THE VEHICLE OPERATOR CANNOT CONTROL THEVEHICLE SPEED BY UP-SHIFTING OR DOWN-SHIFTING, WHICH MAY RESULT IN LOSS OFVEHICLE CONTROL.

Remedy: REPLACE THE ALUMINUM LEVER WITH AN IRON LEVER.

Reported: 1993-12-07 (December 7, 1993)

THE CAB ACCESS GRAB HANDLES HAVE THINNER THAN SPECIFIED WALL THICKNESS AND ARE SUSCEPTIBLE TO FATIGUE FAILURE BREAKING AT THE BEND RADIUS NEAR THE UPPER MOUNTING BOLT HOLE.

Consequence: FAILURE DURING USE OF THE GRAB HANDLES CAN CAUSE AUSER TO FALL RESULTING IN PERSONAL INJURY.

Remedy: WESTERN STAR DEALERS WILL REMOVE AND DESTROY THE RECALLED GRAB HANDLES. NEW HANDLES WILL BE INSTALLED ON THESE VEHICLES.

Reported: 1994-11-09 (November 9, 1994)

THE ALUMINUM REAR SPRING SHACKLE BRACKETS HAVE DEVELOPED CRACKS WHICH CAN LEAD TO SEPARATION OF THE BRACKETS FROM THE FRAME RAIL.

Consequence: THE SUSPENSION CAN DROP DOWN ON ONE SIDE, CAUSING A REDUCTION OF STEERING CONTROL WHICH COULD RESULT IN AN ACCIDENT.

Remedy: DEALERS WILL REPLACE THE SPRING BRACKETS.

Reported: 1995-01-01 (January 1, 1995)

STRAPS HOLDING THE SLEEPER UPPER BUNK IN THE RAISED POSITION CAN RELEASE WITHOUT WARNING.

Consequence: IF THE RESTRAINING STRAP RELEASES SUDDENLY, THEBUNK FALLS WITHOUT WARNING AND CAN STRIKE AN OCCUPANT SITTING IN THE LOWER BUNK CAUSING PERSONAL INJURY.

Remedy: DEALERS WILL REPLACE THE UPPER BUNK RETAINING STRAPS WITH AN IMPROVED AUTOMOTIVE SAFETY BELT STYLE DESIGN STRAP.

Reported: 1995-02-22 (February 22, 1995)

THE BRAKE RETURN SPRINGS ON THE FRONT BRAKES CAN CONTACT THE FRONT HUBS AS THE BRAKE PADS AND DRUMS WEAR, RESULTING IN SPRING FAILURE. A PIECE OF THE FAILED SPRING CAN LODGE IN THE BRAKE CAM CAUSING THE BRAKE TO DRAG AND THE STEERING TO PULL TO ONE SIDE.

Consequence: STEERING PULL FROM THE DRAGGING BRAKE CAN INCREASE THE POTENTIAL FOR A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE FRONT HUBS ON THE AFFECTED VEHICLES.

Reported: 1996-01-05 (January 5, 1996)

THESE HEAVY TRUCKS WERE EQUIPPED WITH EXHAUST MUFFLERS WITHOUT HEAT SHIELDING.

Consequence: SOMEONE WORKING BEHIND THE CAB COULD CONTACT THE HOT MUFFLER CAUSING PERSONAL INJURY. ALSO SOME OF THESE VEHICLES WERE EQUIPPED WITH DECK PLATES WITH NO GRAB HANDLES FOR ACCESS.

Remedy: DEALERS WILL INSTALL MUFFLER SHIELDS AND, WHERE NECESSARY, GRAB HANDLES.