Total Complaints
3 filings
Kenworth T800 · model year
2004 Kenworth T800
3 NHTSA complaints, 1 crash report, and 12 recall campaigns listed for this cohort. A VIN lookup is required to determine whether a specific vehicle has an unrepaired recall.
NHTSA overall rating
Not crash-tested
New Car Assessment Program
- Complaints
- 3
- Recalls
- 12
The verdict
The 2004 Kenworth T800 posts above-average complaint volume among its own model-year siblings.
- 30th pctile
- complaint volume, own model years
- 12
- recall campaigns
The 2004KenworthT800 carries 3 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 1 crash, 2 fires, 1 injury, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.
The most frequently selected component label in reports for the 2004 T800 is vehicle speed control with 1 filings, followed by electrical system (1) and unknown or other (1). Complaint categories reflect owner reports and intake categorization; they do not establish a defect pattern or cause. This cohort has 12 NHTSA recall campaigns listed below. Enter a VIN in NHTSA's official recall lookup to determine whether a specific vehicle has an unrepaired recall.
NHTSA currently has 3 investigation files overlapping the 2004 T800. Owners comparing this cohort against neighboring years should read the complaint-by-year trend as report volume, not a causal diagnosis. Use the related-complaint feed and the official recall lookup when researching a specific vehicle.
3
Complaints
1
Crashes
2
Fires
1
Injuries
0
Deaths
F
PlainCars Safety Score
0/100
2004 Kenworth T800
PlainCars' own composite of NHTSA NCAP crash-test ratings and rollover-risk assessment, each dimension normalized against the federal scale or the full national model-year corpus. Not an official NHTSA figure, and not a substitute for a specific vehicle's VIN-level recall check.
NHTSA Overall Rating N/A
Not rated
NHTSA New Car Assessment Program overall crash-test rating.
Front Crash N/A
Not rated
Frontal barrier crash-test rating.
Side Crash N/A
Not rated
Side barrier and pole crash-test rating.
Rollover Resistance N/A
Not rated
Static stability factor + dynamic rollover test rating.
Rollover Risk N/A
Not reported
NHTSA single-vehicle rollover probability, dynamic test.
Crashes Reported
1 reports
Source
NHTSA ODI
Federal complaints database
Complaints vs. fleet median (215)
At or below the fleet median complaint volume.
Complaints by Component
| Component | Count |
|---|---|
| VEHICLE SPEED CONTROL | 1 |
| ELECTRICAL SYSTEM | 1 |
| UNKNOWN OR OTHER | 1 |
Recalls (12)
09V23900030/06/2009
SERVICE BRAKES, AIR
KENWORTH IS RECALLING 3,423 MY 2004-2009 T2000, T800,T600, W900 AND T660 VEHICLES. INCREASED BRAKE EXCITATION IN A CERTAIN VEHICLE CONFIGURATION WHICH INCLUDES BENDIX DRUM BRAKES, WIDE BASE LOW PROFILE SINGLE TIRES, AND AN AG400 OR AG460 REAR SUSPENSION, DUE TO ITS UNIQUE BRAKE CLOCKING AND CAM TUB
05V18900028/04/2005
SUSPENSION
ON CERTAIN HEAVY DUTY CLASS 8 TRUCKS, THE SUSPENSION HAS TRANSVERSE BEAM CASTINGS THAT MAY FRACTURE UNDER NORMAL LOADS. IF A CASTING BREAKS WHEN THE VEHICLE IS TRAVELING ON A ROADWAY THERE IS THE POTENTIAL FOR PIECES OF THE CASTING TO BECOME PROJECTILES AND THE SUSPENSION'S TRANSVERSE BEAM MAY DROP
08V48500024/09/2008
SUSPENSION
PACCAR IS RECALLING 130 MY 2004-2009 T2000, T800, T600, W900 AND T660 KENWORTH TRUCKS BUILT WITH AN AG400 REAR SUSPENSION, LONG STROKE BRAKE CHAMBERS, AND WIDE BASE TIRES (SUPER SINGLES). THESE VEHICLES MAY DEVELOP AN INCREASE IN LATERAL AND VERTICAL AXLE MOVEMENT. THIS MOVEMENT MAY CAUSE PART OR
05V57000022/12/2005
ENGINE AND ENGINE COOLING
ON CERTAIN TRACTORS EQUIPPED WITH CATERPILLAR DIESEL ENGINES, THE VARIABLE VALVE ACTUATION OIL LINE MAY WEAR AGAINST THE SHARP EDGE OF THE CYLINDER HEAD IF NOT POSITIONED CORRECTLY.
04V36000021/07/2004
ELECTRICAL SYSTEM:WIRING:FRONT UNDERHOOD
ON CERTAIN TRUCKS EQUIPPED WITH A COMBINATION OF CATERPILLAR C11/C13 ENGINES AND AN OPTIONAL LEECE NEVILLE BRUSHLESS ALTERNATOR, A CHAFFING POINT MAY EXIST BETWEEN A HEAT SHIELD ON THE ENGINE AND THE WIRING FOR THE ALTERNATOR.
07V10700016/03/2007
POWER TRAIN:AUTOMATIC TRANSMISSION
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.
04V35600015/07/2004
EQUIPMENT:OTHER:LABELS
CERTAIN TRUCKS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, 'TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS.' THE TIRE PRESSURE WAS OMITTED FROM THE VEHICLE'S CERTIFICATION LABEL.
04V44900013/09/2004
POWER TRAIN:DRIVELINE:UNIVERSAL JOINT
ON CERTAIN TRUCKS BUILT WITH THE OPTIONAL DANA SPL DRIVELINE, THE U-JOINT FASTENERS AT THE OUTPUT YOKE OF THE TRANSMISSION WERE NOT PROPERLY TIGHTENED.
04V17400012/04/2004
ELECTRICAL SYSTEM:WIRING
CERTAIN TRUCKS EQUIPPED WITH EATON FULLER ULTRASONIC TRANSMISSIONS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 102, "TRANSMISSION SHIFT LEVER SEQUENCE, STARTER INTERLOCK AND TRANSMISSION BRAKING EFFECT." THE CAB TRANSMISSION HARNESS COULD HAVE BEEN INCORRECTLY
04V58000010/12/2004
ELECTRICAL SYSTEM:WIRING
ON CERTAIN TRUCKS, THE POWER FEED HARNESS P92-1993 TERMINALS WERE NOT PROPERLY CRIMPED.
05V08400004/03/2005
ENGINE AND ENGINE COOLING
ON CERTAIN TRUCKS EQUIPPED WITH WEBASTO HEATERS, THE BURNER TUBES ARE MADE OF MATERIAL THAT DOES NOT MEET SPECIFICATIONS AND COULD FAIL PREMATURELY.
04V53300002/11/2004
STRUCTURE
ON CERTAIN TRUCKS, SOME OF THE HUCK BOLTS ON THE CAB MAY NOT HAVE BEEN PROPERLY INSTALLED.
Recent Complaints
20110602FireUNKNOWN OR OTHER
2004 KENWORTH T800, UNIT 1 WAS TRAVELING EAST ON THE OHIO TURNPIKE ON THE RIGHT SHOULDER IN THE CONSTRUCTION ZONE. UNIT 1 STATED SHE SMELLED SMOKE COMING FROM UNDERNEATH THE GLOVE BOX AREA. UNIT 1 STOPPED AND GOT OUT OF THE VEHICLE. UNIT 1 BECAME ENGULFED AND WAS PUT OUT BY WATER TRUCK IN THE CONSTRUCTION ZONE. *BF (OHIO TRAFFIC CRASH REPORT # 10-0277-90)
20110429FireELECTRICAL SYSTEM
TL*THE CONTACT OWNS A 2004 KENWORTH T800B TRUCK. THE CONTACT STATED THE GEAR WAS IN THE PARK POSITION WITH THE ENGINE IN OPERATION WHEN SHE EXITED THE VEHICLE. THE CONTACT NOTICED FLAMES EMITTING FROM THE INSTRUMENT PANEL UPON ENTERING THE VEHICLE. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER. THE CAUSE OF FAILURE WAS NOT DETERMINED. THERE WAS A NHTSA RECALL RELATED TO THE DEFECT, CAMPAIGN 04V580000(ELECTRICAL SYSTEM:WIRING). THE VIN WAS NOT INCLUDED IN THE RECALL. THE FAILURE MILEAGE WAS APPROXIMATELY 240,000.
Mileage: 240,000
20050421CrashVEHICLE SPEED CONTROL
SUDDEN FULL UNCONTROLLED ACCELERATION BROUGHT ON BY A REAR END COLLISION WHILE MY VEHICLE WAS STOPPED IN TRAFFIC. DUMP TRUCK WITH ALLISON AUTOMATIC TRANSMISSION. TRANSMISSION TOWER BUTTONS WERE UNRESPONSIVE AND TRUCK WAS ESTIMATED BY WITNESS TO JUMP TO ALMOST IMMEDIATE 60 PLUS. DID NOT STOP UNTIL KEY WAS REMOVED. VIRGINIA DOT INSPECTION APPROX. 2 HOURS LATER FOUND NO PROBLEM AND TRUCK RESPONDED NORMALLY(EXCEPT FOR ACCIDENT DAMAGE) AFTER IT WAS RESTARTED. THERE WAS A SUDDEN SURGE IN THE ENGINE FOR APPROX. 2-3 SECONDS AFTER I WAS REAR ENDED AND THERE WERE NO PRIOR PROBLEMS. *NM
Mileage: 70,000
Compare 2004KenworthT800 to Similar Vehicles
NHTSA Investigations
Vehicle Safety Guides
Frequently Asked Questions
How many complaints does the 2004 Kenworth T800 have?▼
The 2004 Kenworth T800 has 3 NHTSA complaints, 1 crashes, 2 fires, 1 injuries, and 0 deaths reported.
Are there any recalls for the 2004 Kenworth T800?▼
Yes, the 2004 Kenworth T800 has 12 recall(s). The most common affected component is SERVICE BRAKES, AIR. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 Kenworth T800?▼
The most-complained component for the 2004 Kenworth T800 is VEHICLE SPEED CONTROL with 1 complaints. Other frequently reported areas include ELECTRICAL SYSTEM and UNKNOWN OR OTHER.
Is the 2004 Kenworth T800 safe to buy?▼
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?▼
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.
Data vintage: August 2026. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.
Every figure on PlainCars is rendered directly from NHTSA complaint and safety data, no number is typed in by an editor. This year-specific record is rendered from NHTSA ODI, recall, and NCAP rows for the 2004 Kenworth T800; no figure is typed in by an editor. See our editorial standards & corrections policy, the methodology behind these numbers, or report a data error. Data current as of August 2026.
Read our methodology - how this data is sourced, computed, and verified.