Recall 12V235 affects 12 2009 Western Star 4900 trucks for battery cables pinched by cab crossmember. Repair is free at a franchised Western Star dealer.
Western Star is recalling 12 2009 4900 trucks with DD15 engines because a forward cab crossmember leaves too little clearance for cab-mounted battery disconnect switch power cables. During cab movement, the crossmember can pinch those cables, leading to a short, overheating, vehicle fire, and injury; the Western Star dealer repair will be free once available.
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What's wrong?
The battery disconnect switch power cables on the 2009 Western Star 4900 carry electrical power between the cab mounted disconnect switch and the truck's battery system. The disconnect switch gives service technicians and operators a way to cut battery power when the truck is parked or being worked on. These cables need open clearance because the cab moves on its mounts as the truck rides and the cab tilts.
On the affected trucks built with DD15 engines, a forward cab crossmember sits too close to those power cables on standard cab height trucks. A crossmember is a structural bar that supports the cab area. As the cab articulates, that bar can pinch the cables against the cab instead of leaving them free to move.
There is no warning sign before failure. A driver should not count on a dashboard light, sound, or visible symptom before the cable is pinched or damaged.
Who's affected?
| 2009 Western Star 4900 | battery |
|---|---|
| Units affected | 12 |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific truck.
What's the safety risk?
Pinched electrical cables can short to ground, overheat, and start a vehicle fire, creating an injury risk for people inside the cab. If your VIN is included, schedule the recall repair soon and avoid delaying service. Repair will be free at any franchised Western Star dealer once available.
What should I do?
- Check your VIN to confirm your 2009 Western Star 4900 is included in this recall.
- Contact a franchised Western Star dealer and ask whether the battery-disconnect power-cable relocation is open for your truck.
- Ask the dealer to remove and reinstall the power cables in a safer location, and to replace damaged cables free of charge.
- Bring the recall notice if you have it. If not, reference recall number 12V235 when you call.
- Avoid operating the truck until the dealer checks the pinched power-cable risk, since a shorted cable can overheat and start a fire.
What happens at the repair
Once the dealer repair is available, a Western Star technician removes the battery disconnect switch power cables from the area where the forward cab crossmember can pinch them during cab movement. The cables are then reinstalled in a safer location, and any damaged cables are replaced. The work focuses on the power cable routing, not the entire electrical system. Parts and labor will be covered by the recall, so the dealer repair will be free once available.
Timeline
| May 23, 2012 | NHTSA published the recall |
|---|---|
| June 13, 2012 | Owner notification mailed |
Frequently asked questions
What is recall 12V235?
Recall 12V235 covers 12 2009 Western Star 4900 trucks with DD15 engines. A forward cab crossmember leaves too little clearance for cab-mounted battery disconnect switch power cables. During cab movement, the crossmember can pinch those cables. Western Star dealers will move the cables and replace damaged cables for free.
What should I do if my 2009 Western Star 4900 is on this recall?
Check your VIN to confirm your specific truck is included in recall 12V235. If it is, contact a franchised Western Star dealer and ask for the battery disconnect cable relocation. Reference recall number 12V235 when you call. The dealer repair is free.
Is the recall repair free?
Yes. Federal recall law requires the recall repair at no cost, and the recall filing says dealers will relocate the power cables and replace damaged cables free of charge. Use a franchised Western Star dealer for the covered repair.
What is the safety risk?
The safety risk is fire. If the cab crossmember pinches the battery disconnect switch power cables, the cables can short to ground and overheat. That can start a vehicle fire and injure occupants. The free dealer repair moves the cables to a safer location.
When did the recall repair become available?
The recall repair began on June 13, 2012. Because that date has passed, owners can contact a franchised Western Star dealer now to ask for the cable relocation and any needed cable replacement under recall 12V235.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/12V235000 |
|---|---|
| Western Star customer service | 1-800-547-0712 |
| NHTSA recall # | 12V235 |
| NHTSA recall # (full) | 12V235000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Defect / Noncompliance Notice (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on June 2, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →