The 1996 Western Star Conventional has 3 NHTSA recall campaigns affecting an estimated 373 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 1 complaint with NHTSA, most often about the power train. Last updated July 5, 2026.
Recall campaigns
SUSPENSION96V1240031996-08-0136 affected
Defect
THE EQUALIZING BEAM SHAFT OF THE TANDEM AXLE SUSPENSION WERE MANUFACTURED FROM AS-ROLLED SAE4140 STEEL RATHER THAN THE SPECIFIED ANNEALED SAE4140. THESE SHAFTS CAN FRACTURE INSIDE THE BEAM AT THE TOE OF THE WELD.
Consequence
VEHICLES ARE SUBJECT TO VEHICLE TILT AND POSSIBLE ROLLOVER IN THE EVENT THAT BOTH EQUALIZING BEAMS, ON THE SAME SIDE OF THE VEHICLE, EXPERIENCE A SIMULTANEOUS SHAFT FAILURE. AFFECTED SUSPENSIONS CAN ALSO DROP AND CONTACT THE ROAD SURFACE GENERATING SPARKS WHICH COULD IGNITE FLAMMABLE MATERIAL.
Remedy
OWNER NOTIFICATION IS BEING CONDUCTED BY NEWAY ANCHORLOK. DEALERS WILL INSPECT AND REPLACE ALL SUSPENSION SUSPENSION BEAMS WITH SUSPENSION BEAMS CONTAINING APPROPRIATE SHAFTS.
ELECTRICAL SYSTEM96V1000001996-06-17325 affected
Defect
THE WINDSHIELD WIPER ARM CAN INTERFERE WITH THE MAIN CAB DASH HARNESS WHICH PASSES BEHIND THE CENTER DASH SECTION. THE WIPER ARM CAN WEAR THROUGH ONE OR MORE OF THE WIRES IN THE HARNESS AND CAUSE A SHORT CIRCUIT.
Consequence
IN ELECTRONIC ENGINES (CATERPILLAR ONLY) OR DDA ENGINES, THE ENGINE WOULD STOP. IF THE ENGINE WERE TO STOP SUDDENLY WHEN THE VEHICLE WAS TRAVELING AT A HIGH RATE OF SPEED AND MANEUVERING THROUGH TRAFFIC, THERE WOULD BE A POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy
DEALERS WILL MODIFY THE MAIN CAB WIRING HARNESS ROUTING.
SERVICE BRAKES, AIR96V0530001996-03-2712 affected
Defect
THESE TRUCKS WERE NOT BUILT WITH INVERSION VALVES DUE TO A PROGRAMMING ERROR. THE INVERSION VALVE PROVIDES MODULATED SPRING BRAKE APPLICATION DURING EMERGENCY BRAKING WHEN THE "A" PORTION OF THE AIR BRAKE SYSTEM HAS FAILED.
Consequence
IN AN EMERGENCY SITUATION, THE BRAKE SYSTEM WOULD NOT WORK PROPERLY INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy
DEALERS WILL INSTALL AN INVERSION VALVE IN THESE VEHICLES.
Complaints by component
POWER TRAIN:AXLE ASSEMBLY
1
1fires
Total complaints1
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Rear drive axle caught fire. (ohio traffic crash report).”
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1996 Western Star Conventional as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.