VehicleVerdict

2004 Western Star 4900ex problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 0 complaints on file for the 2004 Western Star 4900ex — too few to judge reliability from owner reports alone — but 2 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

0

NHTSA complaints

2

Recalls

0

Investigations

0

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other 4900ex years?

4900ex NHTSA complaints by model year, 2004 highlighted2 complaints2003: 0 complaints2004: 0 complaints2006: 2 complaints2007: 2 complaints
4900ex NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all 4900ex years to avoid →

Does the 2004 Western Star 4900ex have recalls?

2 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

04V590000TransmissionDecember 15, 2004 · 1,095 units

Defect

ON CERTAIN VEHICLES, THERE IS A DEFECT IN THE INTERAXLE DRIVELINE YOKES. THE BOLT HOLES LOCATED ON THE EARWORK OF THE MALE SHAFT YOKES WERE MANUFACTURED WITH AN OVERSIZED MINOR THREAD DIAMETER.

Consequence

THIS CONDITION ALLOWS THE BOLTS USED IN THE HOLES TO BECOME DETACHED WHICH COULD RESULT IN A DRIVELINE SEPARATION. DRIVELINE SEPARATION COULD RESULT IN A VEHICLE CRASH.

Remedy

DEALERS WILL REPLACE THE SUSPECT MALE SHAFT YOKES. THE RECALL BEGAN ON APRIL 4, 2005. OWNERS SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.

04V120000SteeringMarch 8, 2004 · 275 units

Defect

ON CERTAIN TRUCKS AND TRUCK-TRACTORS EQUIPPED WITH TRW DRAG LINK ASSEMBLIES, THE REPLACEMENT CLAMP AND DRAG LINK ASSEMBLIES CONTAIN A POTENTIALLY DEFECTIVE 5/8-11-GRADE B PREVAILING TORQUE HEX NUT. IF THE FINAL TIGHTENING IS LESS THAN 65 LB.-FT., THE CLAMP LOAD WOULD BE UNACCEPTABLY LOW AND COULD COMPROMISE THE INTEGRITY OF THE DRAG LINK.

Consequence

THIS COULD RESULT IN THE BALL SOCKET SEPARATING AND CAUSE LOSS OF STEERING CONTROL, INCREASING THE RISK OF PERSONAL INJURY OR A CRASH.

Remedy

DEALERS WILL REPLACE THE AFFECTED HEX NUT(S). OWNER NOTIFICATION BEGAN ON MAY 21, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.

2004 Western Star 4900ex — common questions

Is the 2004 Western Star 4900ex reliable?

The record is thin — 0 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 2 recalls should be verified as completed.

Does the 2004 Western Star 4900ex have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Western Star 4900ex. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.