CERTAIN MY 2000 THROUGH 2003 THOMAS BUILT HDX AND MVP-ER SCHOOL BUSES MANUFACTURED BETWEEN APRIL 23, 2000, AND NOVEMBER 14, 2003. THE SERVICE AIR BRAKE PEDAL, FOR BOTH NON-ADJUSTABLE AND ADJUSTABLE BRAKE PEDALS, MAY CONTACT THE FRONT STRUCTURE ON THE BUS, LIMITING THE MAXIMUM BRAKE FORCE AVAILABLE.

Consequence & remedy

Consequence: INSUFFICIENT AIR BRAKE PRESSURE MAY CAUSE EXTENDED STOPPING DISTANCES WITHOUT PRIOR WARNING, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy: THOMAS BUILT WILL NOTIFY OWNERS AND REPAIR THE AFFECTED BUSES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2007. OWNERS CAN CONTACT THOMAS BUILT AT 336-889-4871 OR CONTACT FREIGHTLINER AT 800-547-0712.

05V137000 · Steering:linkages:tie Rod Assembly

Apr 1, 2005

CERTAIN 2001-2004 MY THOMAS BUILT MVP-EF, ER TRANSIT, MVP-ER, HD, AND HDX SCHOOL BUSES MANUFACTURED BETWEEN SEPTEMBER 24, 2000, AND MARCH 4, 2004. THE TIE ROD ASSEMBLY CAN FRACTURE AND FAIL, POSSIBLY RESULTING IN COMPLETE SEPARATION.

Consequence & remedy

Consequence: TIE ROD FAILURE CAN POSSIBLY RESULT IN COMPLETE WHEEL SEPARATION AND A VEHICLE CRASH COULD OCCUR.

Remedy: THOMAS BUILT WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE TIE ROD ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN SEPTEMBER 6, 2005. OWNERS MAY CONTACT THOMAS BUILT AT (WE DO NOT YET HAVE A TELEPHONE NUMBER).

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

PE07054 · Emergency Door Handle Failure

Opened Nov 9, 2007 · Closed Mar 4, 2008

Status: closed (inferred from source dates) · Structure:body:door:hinge And Attachments

THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS PRELIMINARY EVALUATIONAFTERBECOMING AWARE THAT FLEETS WERE HAVING HANDLE FAILURES ON THE REAR EMERGENCY DOOR EXIT.THE FAILURE RESULTED IN THE DOOR HANDLE SEPARATING FROM THEDOOR LATCH MECHANISM.WHEN THE HANDLE FAILS, THE REAR EMERGENCY EXIT DOOR CAN NOT BE OPENED FROM OUTSIDE THE BUS.THE FAILURE RESULTS FROM CORROSION OF THE EXTERIOR DOOR HANDLE AROUND THE SECURING ROLL PIN AND SQUARE DRIVE LATCH MECHANISM, CAUSING THE PROTECTIVE FINISH TO CHIP AND FLAKE.CONTINUED CORROSION WEAKENS THE HANDLE AND EVENTUALLY THE HANDLE MAY BREAK WHILE TRYING TO OPEN THE EXIT DOOR.ODI WAS CONCERNED THAT DURING AN EMERGENCY, A PERSON OUTSIDE OF THE BUS WOULD BREAK THE DOOR HANDLE WHILE TRYING TO OPEN THE EMERGENCY EXIT DOOR,POTENTIALLY DELAYING EVACUATION OF THE BUS.UNDER THE SAFETY RECALL, THE ALUMINUM HANDLES WILL BE REPLACED WITH A MORE ROBUST HANDLE.THE RECALL ACTION RESOLVES THE ISSUES RAISED BY THIS INVESTIGATION. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

PE07029 · Side Electrical Fuse Panel Fires

Opened Jun 20, 2007 · Closed Nov 29, 2007

Status: closed (inferred from source dates) · Electrical System

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED THIS INVESTIGATION AFTER BECOMING AWARE OF TWO SCHOOL BUS FIRES THAT STARTED IN THE SIDE MOUNTED ELECTRICAL FUSE PANEL ON A PAIR OF THOMAS BUILT SCHOOL BUSES.THEFLEET OWNER HAD REPORTED THE BUS INTERIORS FILLED WITH SMOKE, CERTAIN ELECTRICAL DEVICES BECAME INOPERATIVE, AND THE BUSES STALLED. THE TWO BUSES INVOLVED IN THE FIRE INCIDENTS HAVE CONSECUTIVE VIN NUMBERS AND THE FIRES WERE SIMILAR, BUT NOT IDENTICAL TO A PREVIOUS RECALL (06V-136) CONDUCTED BY THOMAS BUILT.THESE BUSES WERE NOT INCLUDED IN THE PRIOR RECALL, WHICH INVOLVED A DEFECTIVE POWER DISTRIBUTION MODULE (PDM).AFTER FURTHER TECHNICAL EVALUATION, FREIGHTLINER DECIDED THEY WOULD CONDUCT A SAFETY RECALL TO CORRECT DEFICIENCIES IN THEPREVIOUS RECALL AND ALSO EXPAND THE POPULATION TO CAPTURE ALL AFFECTED BUSES.THE CORRECTIVE ACTION FREIGHTLINER PLANS TO TAKE WILL BE FORWARDED TO ODI WHEN AVAILABLE. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

PE07008 · Restricted Brake Pedal Movement

Opened Feb 12, 2007 · Closed Apr 16, 2007

Status: closed (inferred from source dates) · Service Brakes, Air:controls:foot Control/valve

ODI WAS CONTACTED BY THE NEW YORK DOT WHO REPORTEDSEVERAL BUSES FAILED BRAKING TESTS WHEN BEING TESTED DURING AN ANNUAL INSPECTION. THE SUBJECT SCHOOL BUSES ARE OPTIONED WITH AN ADJUSTABLE FOOT PEDAL POSITIONING DEVICE THAT ALLOWS THE DRIVER TO RAISE AND LOWER THE BRAKE PEDAL HEIGHT TO SUIT HIS/HER SEATING POSITION.WHEN THE LOWEST PEDAL POSITION IS SELECTED (BY A BUTTON ON THE DASHBOARD), NYDOT REPORTED THAT THE BRAKE PEDAL BOTTOMED OUT ON THE FLOOR, THUS PREVENTING A FULL BRAKE PEDAL APPLICATION.THIS RESULTED IN A REDUCTION OF BRAKE TORQUE AT THE WHEEL ENDS.FREIGHTLINER WILL CONDUCT A SAFETY RECALL TO CORRECT THIS PROBLEM.THE REMEDY CALLS FOR A LONGER PEDAL PUSH ROD BEING INSTALLED IN- PLACE OF THE ORIGINAL PUSH ROD. THEY ALSO INCREASED THE POPULATION TO INCLUDE THE MVP-ER MODEL BUSES.THIS RESOLVES THE ISSUE RAISED BY THIS INVESTIGATION. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.