Exterior Lighting Switch Failure/FMVSS 101 & 108

Affected vehicles (9)

Component / system

Defect

PACCAR Incorporated (PACCAR) is recalling certain 2025 Kenworth T180, Peterbilt 535, 567, 2025-2026 Kenworth T280, 2023-2026 Kenworth T380, 2024-2026 Kenworth T480, 2024-2026 Peterbilt 536, 537, and 548 trucks. The exterior lighting switch may fail, resulting in the hazard lights and the instrument display back-light brightness adjustment not functioning. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) numbers 101, "Control and Displays" and 108, "Lamps, Reflective Devices and Associated Equipment."

Risk / consequence

Inoperative hazard lights cannot alert other drivers as intended. In addition, the inability to adjust the brightness on the instrument panel display can make it difficult to see critical safety information or distract the driver. Both scenarios can increase the risk of a crash.

Remedy

Dealers will update the vehicle cab controller unit (VECU) software, free of charge. Owners are advised that a non-responsive switch can be temporarily reset by a key cycle. Owner notification letters were mailed March 26, 2025. Owners may contact Kenworth's customer service at 1-425-828-5888 and Peterbilt's customer service at 1-940-591-4220. PACCAR's numbers for this recall are 25KWB and 25PBB.

Chronology of events

1. Dec 11, 2024

   12-11-24: Safety and compliance notified. Investigation opened. - ELS and MCS are potentially non-functional when engine crank pulls VECU LIN power supply below the 10V shutoff. - When trying to operate MCS3 (Menu Control Switch 3) this will not show in the display. The primary function of the MCS3 is to allow users to navigate through menus or options on the digital display. - When the ELS (Exterior Lighting Switch) is not properly powered on, the vehicle cab controller (VECU) puts the vehicle in a fail-functional mode where the exterior lights are ON. - Hazard lights and backlight brightness adjustment are not functional when ELS is not working. - Driver will need to cycle the key to restore vehicle response. - PLR was created to update the software.

2. Dec 12, 2024

   12-12-24: Confirmed High Beam is functional on truck during non-functional ELS condition.

3. Dec 18, 2024

   12-18-24: The test for the updated software VECU 3.3.14.0 was successful, the ELS and MCS3 functioned with low battery voltage (less than 10V).

4. Jan 2, 2025

   12-20-24: Affected population confirmed. A follow up meeting with engineering was set on 1/2/2025.

5. Jan 6, 2025

   01-06-25: VECU 3.3.14.0 Software released.

6. Jan 9, 2025

   01-09-25: Confirmed that if the MCS3 fails, there is no risk or non-compliance with any regulations.

7. Jan 20, 2025

   01-20-25: Safety committee meeting held, discussed topic. Further clarification and discussion was needed for a decision to be made.

8. Jan 20, 2025

   01-24-25: Safety committee agreed this issue was a regulatory non-compliance safety recall. As of January 20, 2025, PACCAR received 5 warranty claims and 12 reports about trucks in the field that may be related between September 2024 and January 2025. Zero reports of deaths or injuries have been received.

Notification schedule

Dealer notification

MAR 30, 2025 - MAR 30, 2025

Owner notification

MAR 30, 2025 - MAR 30, 2025