New PACCAR Truck Recall: Lighting Risk is Exposed

Paccar Truck Recall Targets 56,575 Kenworth and Peterbilt Units for Lighting Fix

How the Paccar Lighting Bug Puts Drivers at Risk

Engineers found that an incorrectly timed software routine inside the Vehicle Electrical Control Unit (VECU) is at the center of the Paccar truck recall. This defect can stop headlights, brake lamps, reverse lamps, and turn signals from working. When those lights fail, forward visibility drops, and following traffic cannot tell when a truck is slowing, stopping, or backing. The same glitch can also cause lift axles to raise unexpectedly, exposing anyone nearby to injury. 

The National Highway Traffic Safety Administration (NHTSA) says the lighting defect “increases the risk of a crash.” Because the malfunction appears without any warning lights or fault codes, a driver may notice the problem only after the road ahead goes dark.

Models Included in the Paccar Truck Recall

The Paccar truck recall covers Kenworth and Peterbilt vehicles built with EMUX-architecture VECU3 controller (Q21-1157) before May 26, 2025. In total, 56,575 trucks—about 0.3 percent of the population—might carry the defect. Key models are: 

• Kenworth T180 (2025); T280 (2025-26); T380 (2023-26); T480 (2024-26); T680 (2023-26); T880 (2023-26); W990 (2024-26); L770 (2025-26)
• Peterbilt 520 (2023-26); 535 (2025); 536 (2024-26); 537 (2024-26); 548 (2023-26); 567 (2023-26); 579 (2023-26); 589 (2024-26)

Exact VIN ranges appear in the official recall filing.

No Dash Warnings: Troubleshooting the Issue

Paccar told regulators that the VECU software does not trigger a fault code when the timing error occurs. Fleets have reported flickering headlights as the first—and sometimes only—symptom. Because routine pre-trip inspections may not expose an intermittent software failure, service managers are advised to pull trucks into the shop as soon as a driver reports odd light behavior.

Free Software Update and Next Steps

Dealers will install an updated VECU program that corrects the timer logic. The remedy is free and requires no new hardware. While the company has not yet released a mailing date for owner letters, the repair campaign will roll out in phases once distribution of the revised code is complete.

Earlier this year, Paccar issued a smaller lighting-switch recall. Safety analysts say the latest action highlights how critical software integrity has become in modern trucks: a single timer setting can take down every key exterior lamp.

Contact Details for Owners and Fleets

• Kenworth Customer Service: 425-828-5888 — recall 25PACF
• Peterbilt Customer Service: 940-591-4220 — recall 25PACF
• NHTSA Safety Hotline: 888-327-4236 — reference campaign 25V436

Owners who have already paid for repairs related to this defect may be eligible for reimbursement under federal recall rules.

Looking Ahead: Preventive Actions Beyond the Recall

While the Paccar truck recall will restore proper lighting through a software patch, fleets can take additional steps:

1. Add quick light checks to walk-arounds. A 30-second inspection at fuel stops can catch failures that start after a trip begins.
2. Document all dash anomalies. Even without warning lights, noting any flicker helps technicians reproduce faults.
3. Schedule firmware audits. Verifying control-module versions during planned maintenance keeps trucks current when future updates appear.
4. Train drivers on symptom reporting. Clear communication channels speed up shop response times and reduce unscheduled downtime.

Industry observers expect more recalls tied to electronic controls as OEMs load new emissions, safety, and driver-assist features into vehicle networks. For now, the focus remains on getting the affected Kenworth and Peterbilt trucks back on the road with reliable lighting before shorter fall days bring longer stretches of darkness.