Recall 24V509 covers 61 2025 47X, Cascadia, 49X, and 114SD vehicles for tie rod ball stud failure. Free repair at franchised Western Star dealers.
Western Star is recalling 61 2025 47X, 49X, Freightliner Cascadia, and Freightliner 114SD vehicles because a tie rod assembly ball stud in the Composolite EXS20 steerable lift axle suspension can fail after improper heat treatment. The separated ball stud can become a road hazard and increase crash risk; the dealer repair will be free once available.
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What's wrong?
The tie rod assembly on these 2025 47X, Cascadia, 49X, and 114SD vehicles sits on the steerable auxiliary lift axle. That lift axle carries extra load, and the tie rod links the steering parts so the auxiliary wheels point where the truck is being steered. The ball studs in the assembly are pivot points that let the linkage move while staying connected.
The problem is inside those ball studs. Hendrickson reported that its supplier mixed ball studs from an experimental heat treatment process with ball studs approved for production tie rod assemblies. Heat treatment hardens the metal to the required strength. If the ball stud was not hardened correctly, it can break under steering load and the tie rod assembly can fail.
There is no warning sign before failure. The owner is not expected to hear, feel, or see a clear symptom before the ball stud breaks.
Who's affected?
Covers four truck models in the 2025 model year, all tied to the same tie rod on the steerable auxiliary lift axle.
| 2025 Western Star 47X | tie rod (steering linkage) |
|---|---|
| 2025 Freightliner Cascadia | tie rod (steering linkage) |
| 2025 Western Star 49X | tie rod (steering linkage) |
| 2025 Freightliner 114SD | tie rod (steering linkage) |
| Units affected | 61 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching 2025 model does not guarantee inclusion. Check your VIN to confirm whether your specific truck is included.
What's the safety risk?
A separated ball stud becomes a road hazard and increases the risk of a crash. There is no warning sign before failure, so treat this as a repair that needs prompt dealer attention after your VIN is confirmed. Repair will be free at any franchised Western Star dealer once available.
What should I do?
- Check your VIN to confirm your 2025 47X, Cascadia, 49X, or 114SD is included in this recall.
- Wait for the owner letter if you have not received one, then contact a franchised Western Star dealer about the free repair.
- Ask the dealer for the tie-rod assembly replacement that fixes the heat-treated ball stud at risk of separating from the vehicle.
- Reference recall number 24V509 when you call, and bring the recall notice if you have it.
- Avoid driving with unusual steering behavior or visible damage near the steerable lift axle until the vehicle is inspected.
What happens at the repair
At the dealer, a Western Star technician will replace the tie rod assembly covered by recall 24V509. The final dealer repair will be free once it is available for your VIN. The repair targets the tie rod assembly ball stud issue described by DTNA. If you paid out of pocket for this same repair before the recall notice, follow the reimbursement instructions in your owner letter and work through an authorized dealer.
| Reimbursement | Reimbursement available |
|---|
Timeline
| July 3, 2024 | NHTSA published the recall |
|---|---|
| July 23, 2024 | Dealer notification began |
| July 23, 2024 | Dealer notification ended |
| August 26, 2024 | Owner notification mailed |
| September 1, 2024 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 24V509?
Recall 24V509 covers 61 2025 Western Star 47X, Cascadia, 49X, and 114SD vehicles with Composolite EXS20 steerable lift axle suspension assemblies. The tie rod assembly ball stud was improperly heat treated and can fail. Dealers will replace the tie rod assembly for free.
What should I do if my 2025 Western Star 47X, Cascadia, 49X, or 114SD is on this recall?
Check your VIN to confirm your specific vehicle is included in recall 24V509. If it is, contact a franchised Western Star dealer to schedule the tie rod assembly replacement. Reference DTNA recall number F1005 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and dealers will replace the affected tie rod assembly free of charge. You can also contact DTNA customer service at 800-745-8000 with questions about recall F1005.
What is the safety risk?
The tie rod ball stud can separate from the vehicle and become a road hazard, increasing the risk of a crash. If your VIN is included, arrange the dealer repair and ask the service department whether the vehicle needs special handling before the replacement is complete.
When were owners notified about recall 24V509?
DTNA mailed owner notification letters on August 26, 2024. If you bought the vehicle used or never received a letter, the VIN still decides whether recall 24V509 applies. Check your VIN, then call a franchised Western Star dealer with DTNA recall number F1005.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/24V509000 |
|---|---|
| Western Star customer service | 800-745-8000 |
| NHTSA recall # | 24V509 |
| NHTSA recall # (full) | 24V509000 |
Source documents
-
Download Quarterly Report (PDF) - Download Owner Notice (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Misc. Document (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →