Western Star Truck Issues And Fixes

I've had all the same issues, but what really annoys me the most is the little blue light for the a/c. Darn thing quit after 1500 miles. I replaced it more times than I can count until I gave up

 

I've always liked that model.

So they fog on the inside, correct? That's because of high humidity inside the cab as a result of your water leaks. Get the leaks fixed and I bet the fog will lift....so to speak.

My guess is your evaporator may be freezing over due to all the water vapor freezing to it. This restricts the air flow reducing the flow volume which makes the system pretty useless. It just can't remove that much humidity.

TA

 

Most of the repairs done on our trucks are done in our own shop. But on the rare occasion we do take it to the dealer, which is Midway Truck center in Bethel Pa, we generally have awesome service from them.
Our two Stars are only daycabs, so some of the issues we haven't had to deal with. But the HVAC system is very poor, the temp control valve is garbage plastic which usually leaks. And the cable going to it, while we haven't had an issue yet, I could foresee problems as they age. The blower motor is, and always has been noisy. I found spraying some WD-40 in it helps to quiet it some, but it always comes back. And the cab filters are virtually useless. Mine were replaced in January, and two days later I can write my name is the dust on the dash. I have since taped some dryer sheets from home around the filters, and they seem to help, and give a pleasant odor when new. You mentioned the defroster not blowing much air, have you cleaned the cab filter and ductwork? I only suggest this because that alone worked wonders on my truck.
The Windows frosting up hasn't been too hateful, as our temps usually don't go much lower than 0 Fahrenheit. But they do fog up at around 10 degrees or so. I flip both Sun visors down and run the defrost on high for a while, and that usually takes care of it.

I have had the corrosion in the headlight harness, causing the left headlight to go out, while the truck was in warranty. The dealer replaced the plug, and put grease in it, but the next winter, it happened again, so our mechanic cut the plugs off and spliced the wires. Haven't had an issue since then.

The heated mirrors suck. Both mine were replaced under warranty, but it didn't help any. The driver's side has been replaced a second time this past winter and so far it seems to work better than the last two.

One other thing I hate is the defroster vents between the dash and windshield. The large piece of plastic in there works loose over time and rattles like crazy.

Have you had the paint peel off the roof yet? That started after the first winter with mine. I rinse the truck daily, because of the work we do. So I can't attribute that to road salt

But overall, I wont drive any other truck anymore. The Star is by far the nicest riding truck I have ever been in, and aside from the minor issues it has, I still feel it's one of the toughest trucks on the road.

 

That's most likely condensation on the speakers. Finding your leak will most likely help dramatically with a lot of your problems. Check the rain gutter seams to make sure it's not leaking where the fiberglass meets metal. I think Oscar said he ran a bead of silicone in there. I would silicone any opening for wires that you have in the cap. Do you have the little red lights at the top of the sleeper back panel? Qualcomm mount? I would pull back the vinyl that covers the indents where the stacks are and check for intrusion where the cab meets the sleeper.

 

Your whole problem is the auto system. I am sorry to say that. But after having one, that is the problem. I never had the problems I did with the auto with any of the normal manual control systems. I hated that auto system, and the worst part is most of the HVAC duct work and ac compressor, sensors have to be replaced to switch back to manual control.

 

I agree.
I've got a 2016 and a 2012 4900sf.
I've got none of these issues. Both trucks hvac systems work perfect.
Both also just have the manual system.
Only problem I've had is the blue light burnt out in less then a year on the 2012 but after replacing that it's been fine ever since.
I did have a water leak on 1 front window and a leak on the roof. I dropped the head liner and fixed it myself. I resealed 1 airhorn and problem solved.
I don't find the heater fan abnormally loud or do any of my windows ice or fog up. No rattles either.
Honestly your going to find little issues with any new truck. Once you got all of the little new truck gremlins worked out its clear sailing.
I love both my stars, and truly believe they are a very rugged truck and have a lot of great features that are only unique to a WS. Geez , just open and close the door on a Columbia then do the same on a star............... enough said.