2004 KENWORTH T800
12 recalls, 3 complaints - 21 TSBs
09V239000 Jun 30, 2009
SERVICE BRAKES, AIR
Defect Description
KENWORTH IS RECALLING 3,423 MY 2004-2009 T2000, T800,T600, W900 AND T660 VEHICLES. INCREASED BRAKE EXCITATION IN A CERTAIN VEHICLE CONFIGURATION WHICH INCLUDES BENDIX DRUM BRAKES, WIDE BASE LOW PROFILE SINGLE TIRES, AND AN AG400 OR AG460 REAR SUSPENSION, DUE TO ITS UNIQUE BRAKE CLOCKING AND CAM TUB... Read more
Consequence
CRACKING CAN CAUSE A COMPLETE FRACTURE OF THE CAM TUBE, WHICH COULD INCREASE STOPPING DISTANCE AND DECREASE PARKING BRAKE HOLD CAPABILITY.
Remedy
DEALERS WILL INSPECT THE REAR AXLE BRAKES ASSEMBLY, REPLACE CRACKED REAR AXLE BRAKES ASSEMBLY COMPONENTS WHERE REQUIRED, AND INSTALL CAM TUBE SUPPORT BRACKETS ON ALL REAR AXLE WHEEL ENDS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN OR BEFORE JULY 25, 2009. OWNER MAY CONTACT KENWORTH AT 1-425-82... Read more
08V485000 Sep 24, 2008
SUSPENSION
Defect Description
PACCAR IS RECALLING 130 MY 2004-2009 T2000, T800, T600, W900 AND T660 KENWORTH TRUCKS BUILT WITH AN AG400 REAR SUSPENSION, LONG STROKE BRAKE CHAMBERS, AND WIDE BASE TIRES (SUPER SINGLES). THESE VEHICLES MAY DEVELOP AN INCREASE IN LATERAL AND VERTICAL AXLE MOVEMENT. THIS MOVEMENT MAY CAUSE PART OR ... Read more
Consequence
A FAILURE MAY REDUCE VEHICLE BRAKE PERFORMANCE, INCREASING THE RISK OF A CRASH.
Remedy
DEALERS WILL INSTALL THE CAM TUBE SUPPORT BRACKETS ON ALL OF THE REAR AXLE WHEEL ENDS. INSPECT THE REAR AXLE BRAKE ASSEMBLY AND REPLACE IT IF CRACKED. THE RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2008. OWNERS MAY CONTACT KENWORTH AT 1-425-828-5440.
07V107000 Mar 16, 2007
POWER TRAIN:AUTOMATIC TRANSMISSION
Defect Description
ON CERTAIN TRUCKS, THE WIRING, PARTS, OR TRANSMISSION PROGRAMMING REQUIRED FOR THE AUTO NEUTRAL FEATURE TO FUNCTION AS DESIGNED WERE EITHER NOT INSTALLED, CONNECTED, OR PROGRAMMED PROPERLY.
Consequence
IF ANY OF THESE CONDITIONS EXISTS, THE TRANSMISSION WILL NOT AUTOMATICALLY SHIFT INTO NEUTRAL WHEN LEFT IN DRIVE WITH THE PARKING BRAKE SET ENGAGED. THE VEHICLE COULD MOVE WITHOUT WARNING INCREASING THE RISK OF A CRASH.
Remedy
DEALERS WILL INSPECT THE AFFECTED VEHICLES TO ENSURE THE AUTO NEUTRAL FEATURE FUNCTIONS PROPERLY AND, IF NEEDED, WILL MAKE THE NECESSARY REPAIRS FREE OF CHARGE. THE RECALL BEGAN ON MAY 9, 2007. OWNERS MAY CONTACT KENWORTH AT 425-828-5440.
05V570000 Dec 22, 2005
ENGINE AND ENGINE COOLING
Defect Description
ON CERTAIN TRACTORS EQUIPPED WITH CATERPILLAR DIESEL ENGINES, THE VARIABLE VALVE ACTUATION OIL LINE MAY WEAR AGAINST THE SHARP EDGE OF THE CYLINDER HEAD IF NOT POSITIONED CORRECTLY.
Consequence
THE OIL LINE MAY BE CUT ON THE CYLINDER HEAD CAUSING AN OIL LEAK AND A POSSIBLE FIRE.
Remedy
CATERPILLAR, IN CONJUNCTION WITH PACCAR, WILL BE CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN FREE OF CHARGE. OWNERS MAY CALL CATERPILLAR AT 309-675-6496, KENWORTH AT 425-828-5440, OR PETERBILT AT 940-591-4201.
05V189000 Apr 28, 2005
SUSPENSION
Defect Description
ON CERTAIN HEAVY DUTY CLASS 8 TRUCKS, THE SUSPENSION HAS TRANSVERSE BEAM CASTINGS THAT MAY FRACTURE UNDER NORMAL LOADS. IF A CASTING BREAKS WHEN THE VEHICLE IS TRAVELING ON A ROADWAY THERE IS THE POTENTIAL FOR PIECES OF THE CASTING TO BECOME PROJECTILES AND THE SUSPENSION'S TRANSVERSE BEAM MAY DROP... Read more
Consequence
THIS COULD CAUSE SPARKS THAT COULD POTENTIALLY IGNITE AND CAUSE A FIRE.
Remedy
DEALERS WILL INSPECT AND REPLACE THE DEFECTIVE TRANSVERSE BEAM ASSEMBLIES FREE OF CHARGE. THE RECALL BEGAN ON JUNE 10, 2005, WITH LETTERS BEING MAILED TO PETERBILT OWNERS; AND ON JUNE 17, 2005, FOR KENWORTH OWNERS. OWNERS MAY CONTACT PETERBILT AT 940-591-4201 OR KENWORTH AT 425-828-5440.
05V084000 Mar 4, 2005
ENGINE AND ENGINE COOLING
Defect Description
ON CERTAIN TRUCKS EQUIPPED WITH WEBASTO HEATERS, THE BURNER TUBES ARE MADE OF MATERIAL THAT DOES NOT MEET SPECIFICATIONS AND COULD FAIL PREMATURELY.
Consequence
SHOULD THE BURNER TUBE FAIL, THE COOLANT HEATER COULD OVERHEAT, POSSIBLY RESULTING IN A FIRE.
Remedy
DEALERS WILL REPLACE THE SUSPECTED DEFECTIVE PARTS FREE OF CHARGE. THE RECALL BEGAN ON APRIL 4, 2004. OWNERS MAY CONTACT KENWORTH AT 425-828-5440 OR PETERBILT AT 940-591-4201.
04V580000 Dec 10, 2004
ELECTRICAL SYSTEM:WIRING
Defect Description
ON CERTAIN TRUCKS, THE POWER FEED HARNESS P92-1993 TERMINALS WERE NOT PROPERLY CRIMPED.
Consequence
THIS COULD LEAD TO INTERMITTENT POWER LOSS AFFECTING THE ELECTRICAL SYSTEM AND POSSIBLY RESULT IN A FIRE.
Remedy
DEALERS WILL REPLACE THE HARNESS. THE RECALL BEGAN JANUARY 13, 2005. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.
04V533000 Nov 2, 2004
STRUCTURE
Defect Description
ON CERTAIN TRUCKS, SOME OF THE HUCK BOLTS ON THE CAB MAY NOT HAVE BEEN PROPERLY INSTALLED.
Consequence
IF THE HUCK BOLTS ARE NOT PROPERLY INSTALLED, IN AN EXTREME LOADING CONDITION (SUCH AS FRONTAL AND/OR SIDE IMPACT OR A VEHICLE ROLLOVER SITUATION), THE CAB STRUCTURE COULD BE COMPROMISED AND NOT PROVIDE ADEQUATE PROTECTION FOR THE OCCUPANT INCREASING THE RISK OF PERSONAL INJURY.
Remedy
DEALERS WILL INSPECT AND REPLACE THE HUCK BOLTS ON THE CAB ATTACHING STRUCTURE OF THE LEFT-HAND DOOR APERTURE, IF NECESSARY. THE RECALL BEGAN ON NOVEMBER 19, 2004. OWNERS SHOULD CONTACT KENWORTH AT 425-828-5440.
04V449000 Sep 13, 2004
POWER TRAIN:DRIVELINE:UNIVERSAL JOINT
Defect Description
ON CERTAIN TRUCKS BUILT WITH THE OPTIONAL DANA SPL DRIVELINE, THE U-JOINT FASTENERS AT THE OUTPUT YOKE OF THE TRANSMISSION WERE NOT PROPERLY TIGHTENED.
Consequence
IF THE U-JOINTS WERE TO BECOME LOOSE, A PORTION OF THE DRIVELINE COULD BECOME DETACHED FROM THE VEHICLE AND FALL OUT FROM UNDER THE VEHICLE, WHICH COULD CAUSE A CRASH.
Remedy
DEALERS WILL VERIFY THE TORQUE OF THE U-JOINT FASTENERS. PARTS SHOWING EXCESSIVE WEAR WILL BE REPLACED. THE RECALL BEGAN ON NOVEMBER 12, 2004. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.
04V360000 Jul 21, 2004
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
Defect Description
ON CERTAIN TRUCKS EQUIPPED WITH A COMBINATION OF CATERPILLAR C11/C13 ENGINES AND AN OPTIONAL LEECE NEVILLE BRUSHLESS ALTERNATOR, A CHAFFING POINT MAY EXIST BETWEEN A HEAT SHIELD ON THE ENGINE AND THE WIRING FOR THE ALTERNATOR.
Consequence
THIS COULD LEAD TO AN ELECTRICAL SHORT OR ARC SITUATION WHICH COULD RESULT IN AN ENGINE FIRE.
Remedy
DEALERS WILL CHANGE THE ALTERNATOR TO A BRUSH-TYPE ALTERNATOR THAT IS SHORTER IN LENGTH AND PROVIDE THE NECESSARY CLEARANCE TO ALL SURROUNDING COMPONENTS. THE RECALL BEGAN AUGUST 31, 2004. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.
04V356000 Jul 15, 2004
EQUIPMENT:OTHER:LABELS
Defect Description
CERTAIN TRUCKS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, 'TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS.' THE TIRE PRESSURE WAS OMITTED FROM THE VEHICLE'S CERTIFICATION LABEL.
Consequence
IF THE TIRE IS OPERATED IN AN UNDER-INFLATED CONDITION, THE LOAD CARRYING CAPACITY OF THE VEHICLE MAY BE COMPROMISED, INCREASING THE RISK OF A CRASH.
Remedy
OWNERS WILL BE PROVIDED WITH A CORRECTED LABEL. THE RECALL BEGAN AUGUST 12, 2004. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.
04V174000 Apr 12, 2004
ELECTRICAL SYSTEM:WIRING
Defect Description
CERTAIN TRUCKS EQUIPPED WITH EATON FULLER ULTRASONIC TRANSMISSIONS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 102, "TRANSMISSION SHIFT LEVER SEQUENCE, STARTER INTERLOCK AND TRANSMISSION BRAKING EFFECT." THE CAB TRANSMISSION HARNESS COULD HAVE BEEN INCORRECTLY ... Read more
Consequence
THIS COULD CAUSE THE NEUTRAL START FEATURE OF THE TRANSMISSION TO DISABLE ALLOWING THE VEHICLE TO START IN GEAR INCREASING THE POTENTIAL FOR A CRASH.
Remedy
DEALERS WILL REPAIR THE CONNECTIONS IN THE WIRING HARNESS IF NECESSARY. OWNER NOTIFICATION BEGAN ON MAY 7, 2004. OWNERS SHOULD CONTACT KENWORTH AT 1-425-828-5440.
Complaint Statistics
3 total complaints
1 crashes 2 fires 1 injuries
Top Reported Components
| Component | Complaints |
|---|---|
| VEHICLE SPEED CONTROL | 1 |
| ELECTRICAL SYSTEM | 1 |
| UNKNOWN OR OTHER | 1 |
UNKNOWN OR OTHER
Jun 2, 2011
Incident date: Apr 19, 2011
2004 KENWORTH T800, UNIT 1 WAS TRAVELING EAST ON THE OHIO TURNPIKE ON THE RIGHT SHOULDER IN THE CONSTRUCTION ZONE. UNIT 1 STATED SHE SMELLED SMOKE COMING FROM UNDERNEATH THE GLOVE BOX AREA. UNIT 1 STOPPED AND GOT OUT OF THE VEHICLE. UNIT 1 BECAME ENGULFED AND WAS PUT OUT BY WATER TRUCK IN THE CONS... Read more
Fire
ELECTRICAL SYSTEM
Apr 29, 2011
Incident date: Feb 14, 1992
TL*THE CONTACT OWNS A 2004 KENWORTH T800B TRUCK. THE CONTACT STATED THE GEAR WAS IN THE PARK POSITION WITH THE ENGINE IN OPERATION WHEN SHE EXITED THE VEHICLE. THE CONTACT NOTICED FLAMES EMITTING FROM THE INSTRUMENT PANEL UPON ENTERING THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES. THE VE... Read more
Fire
VEHICLE SPEED CONTROL
Apr 21, 2005
Incident date: Apr 20, 2005
SUDDEN FULL UNCONTROLLED ACCELERATION BROUGHT ON BY A REAR END COLLISION WHILE MY VEHICLE WAS STOPPED IN TRAFFIC. DUMP TRUCK WITH ALLISON AUTOMATIC TRANSMISSION. TRANSMISSION TOWER BUTTONS WERE UNRESPONSIVE AND TRUCK WAS ESTIMATED BY WITNESS TO JUMP TO ALMOST IMMEDIATE 60 PLUS. DID NOT STOP UNTIL ... Read more
Crash
1 injured
Technical Service Bulletins, 2004 KENWORTH T800
21 manufacturer communications from 14 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL | 4 |
| 061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER | 2 |
| 110000 ELECTRICAL SYSTEM | 2 |
| 350000 EQUIPMENT | 2 |
| 356000 EQUIPMENT ADAPTIVE/MOBILITY | 2 |
| 063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL | 1 |
| 136000 VISIBILITY:WINDSHIELD WIPER/WASHER | 1 |
| 063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM | 1 |
02-160
Feb 10, 2021
356000 EQUIPMENT ADAPTIVE/MOBILITY
Information Only a?? Windshield washer pumps have a high No Trouble Found rate. Washer pumps may fail to spray due to a clogged filter.
02-160
Feb 10, 2021
350000 EQUIPMENT
Information Only a?? Windshield washer pumps have a high No Trouble Found rate. Washer pumps may fail to spray due to a clogged filter.
02-160
Feb 10, 2021
136000 VISIBILITY:WINDSHIELD WIPER/WASHER
Information Only a?? Windshield washer pumps have a high No Trouble Found rate. Washer pumps may fail to spray due to a clogged filter.
02-160
Feb 10, 2021
130000 VISIBILITY
Information Only a?? Windshield washer pumps have a high No Trouble Found rate. Washer pumps may fail to spray due to a clogged filter.
DOR-W5T2V-01
Dec 20, 2020
356000 EQUIPMENT ADAPTIVE/MOBILITY
This SKU is a Climate Control Module. The customer communication requested return of unsold inventory to inspect alignment pins and knobs. The alignment pins may be weak which cause them to break and knob material may be weak which could
DOR-W5T2V-01
Dec 20, 2020
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER
This SKU is a Climate Control Module. The customer communication requested return of unsold inventory to inspect alignment pins and knobs. The alignment pins may be weak which cause them to break and knob material may be weak which could
32-015
Jun 8, 2020
110000 ELECTRICAL SYSTEM
Information Only: This bulletin provides dealers with a battery warranty quick reference guide to ensure the appropriate tests for battery warranty are performed in order to prevent battery warranty claims filed with incorrect or incomplet
32-016
Mar 17, 2020
350000 EQUIPMENT
Information Only: Proper jump-starting voltage will eliminate high voltage related issues and equipment damage.
34-085
Mar 3, 2020
180000 VEHICLE SPEED CONTROL
Information Only a?? Vehicles may have the connector seals on the wheel speed sensor incorrectly installed, which may lead to water intrusion and corrosion in some vehicles.
34-085
Mar 3, 2020
110000 ELECTRICAL SYSTEM
Information Only a?? Vehicles may have the connector seals on the wheel speed sensor incorrectly installed, which may lead to water intrusion and corrosion in some vehicles.
01-075
Nov 6, 2019
060000 ENGINE AND ENGINE COOLING
Information Only: This bulletin provides guidance for repairing an air-conditioning system after internal failure of the A/C compressor.
TIB-13-040
Feb 27, 2015
023000 SUSPENSION:MULTIPLE AXLE
KENWORTH: SOME TRUCKS FAILED TO MEET COMPANY STANDARDS FOR AIR VOLUME LIFT AXLE AND THE COMPANY WILL INCREASE AIR VOLUME FOR WORTHWHILE IMPROVEMENT TO EXCEED GOVERNMENT FMVSS 121. MODEL T800, W900. *PE SEE DOCUMENT SEARCH BUTT
TIB-E-055
Jul 9, 2012
061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER
KENWORTH: OIL COLLECTION AT CAC INTAKE PIPE IS CAUSED BY AN IMBALANCE IN TURBOCHARGER PRESSURES. MODELS T660, T800, T700, AND W900. *PE
TIB-E011
Dec 15, 2010
063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
PACCAR: ENGINEERING STANDARDS HAVE CHANGED AND THERE ARE NOW ENGINES WITH HEAT TREATED BOLTS. *RM
TIB-E-009
Dec 2, 2010
061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL
PACCAR: A SOFTWARE UPDATE IS CAUSING THE CHECK ENGINE LIGHT TO COME ON. *RM
TIB-02-107
Oct 7, 2009
162800 STRUCTURE:BODY:HOOD
KENWORTH TRUCK SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. METTON HOOD REPAIR CAMPAIGN. HOOD REINFORCEMENT CHANNEL CRACKING DUE TO UNIQUE, HARSH SERVICE CONDITIONS. NOTE: CODE 02107 IS NOT AN INSTRUCTION FOR DEALERS TO
TSB-41-13
Nov 5, 2008
061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL
KENWORTH TRUCK: AIR INTAKE FOR PRE-2007 ISM ENGINE IN T800 SHORT HOOD CHASSIS. PREMATURE ENGINE WEAR DUE TO DIRT INGESTION INVOLVING THE 2002-07 T800 SHORT HOOD (SH) MODEL WITH CUMMINS ISM ENGINE. *PE
TIB-44-17
Oct 23, 2008
061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL
KENWORTH TRUCKS: REDUCED ENGINE POWER FROM FUEL STARVATION. ANY MODEL KENWORTH EQUIPPED WITH THE 2007 EMISSIONS COMPLIANT ISX ENGINE AND OPTIONAL DAVCO 382 FUEL FILTER, BUILT PRIOR TO 8/11/08, *PE
TIB-44-17
Oct 23, 2008
063100 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
KENWORTH TRUCKS: REDUCED ENGINE POWER FROM FUEL STARVATION. ANY MODEL KENWORTH EQUIPPED WITH THE 2007 EMISSIONS COMPLIANT ISX ENGINE AND OPTIONAL DAVCO 382 FUEL FILTER, BUILT PRIOR TO 8/11/08, *PE
TIB-41-12
Oct 16, 2008
061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL
KENWORTH TRUCKS: THE INLET PIPE CONNECTIONS FOR ISX ENGINES. THE KENWORTH AIR INLET PIPE TO THE ISX TURBO MAY BECOME DETACHED. CHASSIS AFFECTED T2000, T800, AND W900. MODEL YEARS UNKNOWN. *PE
TIB-41-12
Oct 16, 2008
061120 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:TURBO/SUPERCHARGER
KENWORTH TRUCKS: THE INLET PIPE CONNECTIONS FOR ISX ENGINES. THE KENWORTH AIR INLET PIPE TO THE ISX TURBO MAY BECOME DETACHED. CHASSIS AFFECTED T2000, T800, AND W900. MODEL YEARS UNKNOWN. *PE
KENWORTH T800 - All Years Overview
Complete safety history for the KENWORTH T800 across all model years (1987, 2025).
318
Total Recalls
49
Total Complaints
0
Investigations
5
Reported Crashes
7
Reported Fires
0
Reported Deaths
KENWORTH T800 - Year by Year
Compare recalls and complaints across model years. Click any year to see full details.
| Year | Recalls | Complaints | |
|---|---|---|---|
| 2025 | 1 | 0 | View |
| 2024 | 4 | 0 | View |
| 2023 | 1 | 0 | View |
| 2022 | 1 | 0 | View |
| 2021 | 1 | 0 | View |
| 2020 | 9 | 0 | View |
| 2019 | 8 | 0 | View |
| 2018 | 11 | 1 | View |
| 2017 | 8 | 0 | View |
| 2016 | 12 | 1 | View |
| 2015 | 12 | 0 | View |
| 2014 | 12 | 0 | View |
| 2013 | 8 | 0 | View |
| 2012 | 10 | 1 | View |
| 2011 | 13 | 1 | View |
| 2010 | 11 | 1 | View |
| 2009 | 19 | 2 | View |
| 2008 | 25 | 2 | View |
| 2007 | 21 | 1 | View |
| 2006 | 13 | 4 | View |
| 2005 | 12 | 6 | View |
| 2004 (current) | 12 | 3 | |
| 2003 | 7 | 1 | View |
| 2002 | 6 | 0 | View |
| 2001 | 10 | 1 | View |
| 2000 | 10 | 6 | View |
| 1999 | 12 | 4 | View |
| 1998 | 8 | 1 | View |
| 1997 | 9 | 8 | View |
| 1996 | 8 | 1 | View |
| 1995 | 5 | 2 | View |
| 1994 | 3 | 2 | View |
| 1993 | 1 | 0 | View |
| 1992 | 1 | 0 | View |
| 1991 | 4 | 0 | View |
| 1990 | 3 | 0 | View |
| 1989 | 3 | 0 | View |
| 1988 | 2 | 0 | View |
| 1987 | 2 | 0 | View |