Verdict · NHTSA data
Limited data — recalls on file
NHTSA has just 0 complaints on file for the 1991 Western Star Conventional — too few to judge reliability from owner reports alone — but 5 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.
0
NHTSA complaints
5
Recalls
0
Investigations
0
Crash-involved
0
Fires reported
0
Injuries
0
Deaths
—
NCAP overall
5 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.
Defect
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.
Defect
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.
Defect
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.
Defect
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.
Defect
THE BURN RATE FOR THE MATTRESS TICKING EXCEEDS THE 4 INCHES PER MINUTE REQUIREMENT OF FMVSS 302, "FLAMMABILITY OF INTERIOR MATERIALS."
Consequence
EXCESSIVE BURN RATES OF INTERIOR MATERIALS PRESENTS ANINCREASED RISK OF INJURY TO VEHICLE OCCUPANTS IN CASE OF A FIRE.
Remedy
REPLACE THE MATTRESS TICKING WITH NEW COVERS THAT COMPLY WITH THE STANDARD.
The record is thin — 0 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 5 recalls should be verified as completed.
Yes — NHTSA lists 5 recall campaigns affecting the 1991 Western Star Conventional. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.
Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.
Compiled by Sharon Ben-Moshe, Founder.