Daimler Truck North America has recalled over 21,000 Western Star trucks due to a potentially dangerous fire risk caused by faulty battery connections that could leave truck owners in danger.
At a Glance
- 21,560 Western Star trucks (models 47X and 49X from 2020-2026) are being recalled due to fire hazards
- The issue stems from incorrectly installed positive junction point studs in battery connections
- Warning signs include slow starting, no-crank conditions, and visible corrosion around battery connections
- Five instances of battery corrosion and related fires occurred between March 2023 and March 2024
- Repairs will be provided free of charge at authorized service facilities
Widespread Recall Affects Thousands of American Trucks
Daimler Truck North America officially initiated a recall of 21,560 Western Star trucks on May 12, 2025, after discovering a serious manufacturing defect that could lead to vehicle fires. The recall specifically targets Western Star 47X trucks manufactured between 2021 and 2026 (approximately 12,000 vehicles) and 49X trucks built between 2020 and 2026 (around 9,500 vehicles). These heavy-duty commercial vehicles, widely used across America’s highways for various industrial applications, now require inspection and potential repair to address the safety concern.
The National Highway Traffic Safety Administration (NHTSA) has assigned recall number 25V326 to this safety action. Despite Daimler’s estimate that only about 1% of the recalled trucks actually have the defect, the widespread recall demonstrates the company’s commitment to eliminating any potential safety hazards affecting American truck operators. Truck owners can also contact Daimler Truck North America’s customer service directly at 800-547-0712 and reference recall number F1020 for additional information.
Daimler Trucks has issued a major recall affecting over 21,000 Western Star 47X and 49X trucks from model years 2020–2026.
The issue involves a battery connection stud that may have been installed incorrectly, creating a serious fire risk due to potential short circuits.… pic.twitter.com/NGWChvYCSb
— Truck Driver News (@TruckDriverNews) June 2, 2025
Technical Issue and Warning Signs
The core problem involves incorrectly installed positive junction point studs in the battery connection, which can lead to dangerous short circuits. This manufacturing defect creates the potential for electrical failures that could progress to fires. According to documentation filed with safety regulators, the company has received 36 potentially related warranty claims and 15 field reports between March 2023 and March 2025, highlighting a persistent issue that required manufacturer attention.
“Drivers may experience a slow or no crank when starting their vehicle,” the report noted. “Driver may visually observe corrosion present around the stud and/or cable lug.”
Reports include five instances of battery corrosion and related incidents of fire and melted cables between March 2023 and March 2024. While no deaths or injuries have been reported, the risk of truck fires represents a significant safety concern for operators and other vehicles sharing the roadways. Truck owners who notice electrical issues, starting problems, or visible corrosion around battery connections should have their vehicles inspected immediately rather than waiting for the formal recall notice.
Manufacturer Response and Recall Timeline
The path to this recall wasn’t straightforward. In August 2024, Daimler initially decided against a field action, determining “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 additional reports of fires and melted studs, the manufacturer revived its investigation, ultimately leading to the current recall decision. Daimler has already taken steps to prevent similar issues in new production, including updating manufacturing processes and implementing additional inspections to ensure proper cable lug orientation. A comprehensive remedy program for affected vehicles is currently in development, though specific details about the repair process have not yet been announced.
Truck owners will receive official notification by mail in the coming weeks, and all repairs will be provided free of charge at authorized Daimler Truck North America service facilities. This recall represents another challenge for America’s vital trucking industry, which continues to face equipment shortages, regulatory pressures, and increasing operational costs while maintaining the nation’s critical supply chains.
