Recall 25V181 covers 238 2021-2025 T680, 579, and 520 trucks for high-voltage contactors that open. Free software and harness repair at a franchised Kenworth dealer.
Kenworth is recalling 238 2021-2025 T680, 579, and 520 trucks because the high-voltage contactors can open and cut high-voltage power while the truck is in use. That loss of drive power increases crash risk, and Kenworth dealers will complete the free recall repair.
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What's wrong?
On affected 2021-2025 Kenworth T680, 579, and 520 battery electric trucks, the Power Control and Accessory Subsystem is part of the high-voltage power distribution system. It helps route battery power through electrical contactors, which are heavy-duty switches that connect high voltage to the propulsion system when the truck is ready to drive.
The problem is in the high voltage interlock loop, a safety circuit that confirms high-voltage connections are secure. In the current circuit design, an interruption as short as 10 ms can cause a loss of signal. That opens the electrical contacts, cuts high voltage, and causes a sudden loss of drive power. Cycling the key does not reset the contactors.
There is no warning sign before failure. The first thing a driver notices can be the sudden loss of drive power after the contactors open.
Who's affected?
Covers three electric truck models across the 2021-2025 model years, all tied to the same Power Control and Accessory Subsystem.
| 2021 Kenworth T680 | electric propulsion system |
|---|---|
| 2022 Peterbilt 579 | electric propulsion system |
| 2022 Peterbilt 520 | electric propulsion system |
| 2025 Peterbilt 520 | electric propulsion system |
| 2025 Peterbilt 579 | electric propulsion system |
| 2025 Kenworth T680 | electric propulsion system |
| 2024 Peterbilt 579 | electric propulsion system |
| 2024 Kenworth T680 | electric propulsion system |
| 2024 Peterbilt 520 | electric propulsion system |
| 2023 Kenworth T680 | electric propulsion system |
| 2023 Peterbilt 579 | electric propulsion system |
| 2023 Peterbilt 520 | electric propulsion system |
| 2022 Kenworth T680 | electric propulsion system |
| Units affected | 238 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific truck is included in this recall.
What's the safety risk?
A loss of drive power increases the risk of a crash because the truck can lose momentum in traffic. There is no warning sign before failure. Drive cautiously, and schedule the recall repair soon if your VIN is included. Repair is free at any franchised Kenworth dealer.
What should I do?
- Check your VIN to confirm your 2021-2025 Kenworth T680, 579, or 520 is included in this recall.
- Contact a franchised Kenworth dealer to schedule the free repair.
- Schedule the software update and electrical-harness replacement that keeps the HV contactors from opening and cutting drive power.
- Bring the recall notice if PACCAR mailed one. If not, reference recall number 25V181 when you call.
- Drive cautiously until the repair is complete, and move out of traffic safely if the truck loses drive power.
What happens at the repair
At the dealer, a Kenworth technician updates the truck software and replaces the electrical harness covered by recall 25V181. The software update and harness replacement are free under the recall. PACCAR used its general reimbursement plan on file, so documented out-of-pocket repairs tied to this recall can be submitted through that plan. Bring repair invoices and payment records to the service desk or contact Kenworth customer service for claim instructions.
| Reimbursement | Reimbursement available |
|---|
Timeline
| March 24, 2025 | NHTSA published the recall |
|---|---|
| May 13, 2025 | Owner notification mailed |
| May 23, 2025 | Dealer notification began |
| May 23, 2025 | Dealer notification ended |
| May 23, 2025 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 25V181?
Recall 25V181 covers 238 2021-2025 Kenworth T680, 579, and 520 trucks with high-voltage contactors that can open and cause sudden loss of drive power. Loss of drive power increases crash risk. Dealers will update the software and replace the electrical harness for free.
What should I do if my 2021-2025 Kenworth T680, 579, or 520 is on this recall?
Check your VIN to confirm your specific truck is included in recall 25V181. If it is, contact a franchised Kenworth dealer to schedule the software update and electrical harness replacement. Reference recall number 25V181 and Kenworth recall number 25KWC when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. For recall 25V181, dealers will update the software and replace the electrical harness free of charge at a franchised Kenworth dealer.
What is the safety risk in recall 25V181?
The safety risk is sudden loss of drive power. The high-voltage contactors can open, cutting high voltage to the propulsion system. If that happens while the truck is moving, the loss of drive power increases crash risk.
When were owners notified about recall 25V181?
Owner notification letters were mailed May 13, 2025. If you did not receive a letter, check your VIN anyway, especially if you bought the truck used or your address changed after purchase.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V181000 |
|---|---|
| Kenworth customer service | 1-940-591-4220 |
| NHTSA recall # | 25V181 |
| NHTSA recall # (full) | 25V181000 |
Source documents
-
Download Quarterly Report (PDF) - Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Owner Notice (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →