2007 Kenworth T800 Recall

This recall is for certain used trucks that Trojan Welding Inc. converted to dump trucks in 2019 and 2020. The company applied the National Safety Mark and a new compliance label that indicated the trucks were built in 2020. This is not allowed under the Motor Vehicle Safety Act.

Contrary to Trojan's labelling, the modified trucks do not meet all requirements under the Motor Vehicle Safety Act.

Trojan Welding will notify the owner(s) in writing and arrange for the removal of the incorrect compliance label and National Safety Mark.

On certain trucks equipped with a Caterpillar C15 diesel engine, the Diesel Particulate Filter (DPF) combustion tube may fail. This could result in a vehicle fire causing property damage and/or personal injury. Correction: Dealers will replace the DPF combustion tube.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles equipped with a PACCAR MX engine, the oil module centrifugal spinner filter cap may become loose, possibly allowing the cap to come off and engine oil to partially discharge from the oil module onto nearby exhaust components. The discharge of engine oil onto hot exhaust components could result in a fire causing property damage and/or personal injury. Correction: Dealers will re-torque the oil module filter cap and install a secondary retention device on the secondary centrifugal spinner filter cap.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the bearing surfaces of the extended lube universal joint that attaches the inter-axle driveline to the drive axle may become prematurely worn due to breakdown of the lubrification and/or excessive heat. Prematurely worn bearing surfaces may result in the u-joint becoming loose and/or binding. If undetected, the condition may result in universal joint failure, allowing the inter-axle driveline to detach from the axle, which may cause the vehicle to become disabled in the roadway. Lost propulsion, in conjunction with traffic, road conditions, and the driver's reactions, could increase the risk of a crash. In addition a driveline component separating from the vehicle could strike another vehicle, stationary object, or bystander, causing property damage and/or personal injury. Correction: Dealers will inspect and, if necessary, replace the interaxle driveline universal joint.

A failure of this component (powertrain) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

Certain vehicles may suffer cracking of various brake assembly components (i.e. brake cam tube mounting flanges, brake air chamber bracket, brake air chamber, brake spider). Over time, this cracking can cause a complete fracture of the cam tube, which could increase stopping distances and decrease parking brake hold capability. A reduction of braking capability could increase the risk of a crash causing property damage, personal injury or death. Correction: Dealers will inspect the rear axle brake assembly, replace cracked rear axle brake components where required, and install cam tube support brackets on all rear axle wheel ends.

A failure of this component (brakes) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles equipped with a Caterpillar C15 engine, the Variable Valve Actuation (VVA) oil line may wear against the P-clip retaining the oil line. An oil leak could result in a vehicle fire causing property damage and/or personal injury. Correction: Caterpillar dealers will replace the VVA oil line with an updated version.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the caliper mounting fasteners attaching the air disc brake caliper assembly to the torque plate may have received insufficient tightening torque during the assembly process. Insufficient torque may allow the caliper mounting fasteners and/or the caliper itself to become loose. This could cause the brake on the affected wheel end to become inoperable. Extended stopping distance could result in a vehicle crash causing property damage, personal injury or death. Correction: Dealers will replace caliper mounting fasteners and inspect the caliper assembly.

A failure of this component (brakes) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

Certain vehicle configuration which includes an AG400 rear suspension, long stroke brake chambers, and wide base tires may develop an increase in lateral and vertical axle movement. This movement may cause part or parts of the brake assembly to develop fatigue cracks, possibly resulting in the failure of part or parts within the brake assembly. A failure may reduce vehicle brake performance, increasing the risk of a crash causing personal injury or death. Correction: Dealers will affect repairs.

A failure of this component (suspension) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, the inadequate stiffness of the Diesel Particulate Filter (DPF) bracket could result in the separation of the DPF from the chassis, which could result in personal injuries or death to motorists or bystanders. Correction: Caterpillar dealers will replace bracket as necessary.

A failure of this component (other) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the trailer cable mounting bracket has a "U-shaped" cut-out that only partially supports the trailer cable connection. This may allow the moulded boot and electrical ground pin to partially or completely pull away from the 7-way socket. Partial or complete detachment can cause reduced water resistance and potential loss of electrical ground. There is also a possibility the trailer lights may fail to illuminate without the operator's knowledge. Reduced visibility during hours of darkness could result in a vehicle crash, causing personal injury or death. Correction: Dealers will install a reinforcement bracket.

A failure of this component (lights and instruments) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles, the slack adjuster may develop a fatigue crack and fail. This would render the slack adjuster inoperative, and reduce braking effectiveness. Extended stopping distances may result in a vehicle crash, causing property damage, and/or personal injury or death. Correction: Dealers will inspect and, where necessary, replace the slack adjusters.

A failure of this component (brakes) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain vehicles equipped with Caterpillar C7 and C9 diesel engines, fuel pump failure can dilute the engine oil with fuel and cause the turbocharger to fail, leading to a loss of throttle control and excessive smoke. Either condition could result in a vehicle crash causing property damage, personal injury or death. Correction: Authorized Caterpillar dealers will replace the fuel pump.

A failure of this component (fuel system) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, the removable front tow hitch assembly may fail. This could result in personal injury or property damage if the assembly failed during the un-decking or towing of a vehicle. Correction: Dealers will replace the tow pin assembly with a revised version.

A failure of this component (other) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks equipped with Caterpillar C11, C13 and C15 engines, the oil fill cap can become dislodged due to cap damage or improper installation. The cap can become lodged in the u-joint of the steering driveline and steering gear, causing difficulty steering the vehicle and/or complete steering lock-up. A loss of steering control can result in a vehicle crash causing injury or death. Correction: Dealers will install an oil cap retention chain to C11 engines and will modify the existing retention chain anchor point on C13 and C15 engine. Damaged oil fill caps will be replaced.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, when the ignition key is in the 'ON' position, the pre-heater, located in the fuel filter base, is energized. If this pre-heater is energized while maintenance is being performed on the fuel filter, diesel fuel could ignite within the filter housing. A fire within the fuel filter housing may spread possibly resulting in property damage or personal injury. Correction: Dealers will inspect and, if required, replace the fuel heater assembly.

A failure of this component (fuel system) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

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. If any of these conditions exists, the transmission will not automatically shift into Neutral when left in Drive with the parking brake engaged. The vehicle could move without warning increasing the risk of a crash. Correction: Dealers will inspect and, if needed, make the necessary repairs.

A failure of this component (powertrain) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

Certain trucks fail to comply with the requirements of CMVSS 121 - Air Brake Systems. In designing a Primaax suspension into certain models, engineers relocated the single relay valve. The relocation increased overall air line length, exceeding the limit for the single valve system. This would result in delayed brake application which could cause a vehicle crash with injury or death. Correction: Dealers will convert vehicles from a single relay valve to a dual relay valve system.

A failure of this component (brakes) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, the axle housing may have been manufactured with steel that was out of specification (9.5mm thick instead of 11mm thick), which could result in a fatigue failure over time. If failure occurs, the axle may lock-up or the end of the axle could come off, which may result in a vehicle crash with injury or death. Correction: Dealers will inspect and, if required, replace the axles.

A failure of this component (other) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, the trailer light wiring harness may have been routed incorrectly during vehicle assembly. This could cause the wires within the harness plug to be pulled away from the chassis plug, resulting in an intermittent or complete electrical power loss to the trailer. This would cause a loss of all trailer lighting and ABS function. Inoperative side markers and tail lamps would make the trailer less visible to other drivers during times of reduced visibility. A loss of brake lamp function would not allow a following driver to know when the brakes have been applied, and a rear-end crash could occur as a result. Correction: Dealers will re-route the wiring harness.

A failure of this component (electrical) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, an incorrect pressure sensing switch was installed in the cruise control system during vehicle assembly. A light brake application will not de-activate the cruise control and the system will have to be shut off by the dash switch. Failure to deactivate the cruise control could cause a vehicle crash with injuries or death. Correction: Dealers will install the correct switch.

A failure of this component (engine) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).

On certain trucks, the tilt locking mechanism on the steering column may disengage, preventing the steering column from locking into predetermined positions. Should the locking mechanism disengage, the tilting travel of the column would be unrestricted. This could allow the steering wheel to impact the dash and limit the movement of the steering wheel. Correction: Dealers will install a bracket designed to restrain the tilting mechanism and prevent it from disengaging.

A failure of this component (steering) may increase the risk of a crash or injury.

Authorized dealerships will inspect the vehicle and complete all necessary repairs free of charge (parts and labor).