When problems were reported
Mileage at the reported incident
Limited mileage data: 0 of 0 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
NHTSA owner reports · September 18, 2026 snapshot.
Official recalls
10Feb 26, 2008
DAIMLER TRUCKS IS RECALLING 243,435 MY 1995-2008 THOMAS BUILT SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 1994, AND MARCH 10, 2008. (ADDITIONAL BUSES HAVE BEEN ADDED TO THIS RECALL CAMPAIGN. PLEASE SEE SUPPLEMENTAL REPORT NO. 4) THE EMERGENCY EXIT DOOR HANDLE BEGINS CORRODING AROUND THE SECURING ROLL PIN AND SQUARE DRIVE MECHANISM CAUSING THE PROTECTIVE FINISH TO CHIP AND FLAKE. CONTINUED CORROSION AND PITTING WEAKENS THE HANDLE. HANDLES WEAKENED BY CORROSION MAY BREAK WHILE TRYING TO OPEN THE DOOR FROM THE EXTERIOR.
Consequence & remedy
Consequence: IN THE EVENT OF AN EMERGENCY, A PERSON ON THE OUTSIDE OF THE BUS MAY BREAK THE DOOR HANDLE TRYING TO OPEN THE EMERGENCY EXIT POTENTIALLY DELAYING EVACUATION AND INCREASING THE RISK OF PERSONAL INJURY TO THE VEHICLE'S OCCUPANTS.
Remedy: DAIMLER TRUCKS WILL NOTIFY OWNERS AND WILL REPLACE THE HANDLES WITH A MORE ROBUST HANDLE FREE OF CHARGE. REPAIRS WILL BE PERFORMED BY THOMAS BUILT BUSES DEALERSHIPS. THE RECALL BEGAN ON AUGUST 18, 2008, AND NOTIFICATION FOR THE REVISED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT APRIL 29, 2009. OWNERS MAY CONTACT THOMAS BUILT AT 336-889-4871.
Nov 29, 2007
CERTAIN 2001 THROUGH 2008 THOMAS BUILT FS-56, ER, MVP ER, HDX, AND MVP EF SCHOOL BUSES MANUFACTURED FROM OCTOBER 23, 2000, THROUGH JANUARY 24, 2006, EQUIPPED WITH TYCO PC BOARD AND TYPE II AUTO RESET CIRCUIT BREAKERS. TYPE II AUTO RESET CIRCUIT BREAKER TEMPERATURES MAY EXCEED THE RATING OF THE TYCO PC BOARD CAUSING THE BOARDS TO MELT POTENTIALLY RESULTING IN A VEHICLE FIRE.
Consequence & remedy
Consequence: A VEHICLE FIRE CAN OCCUR POSSIBLY RESULTING IN A CRASH.
Remedy: THOMAS BUILT WILL NOTIFY OWNERS AND REPAIR THE BUSES BY REPLACING THE TYPE II AUTO RESET CIRCUIT BREAKERS WITH MANUAL CIRCUIT BREAKERS, AND THE JUMPER CABLE. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT THOMAS BUILT CUSTOMER SUPPORT OFFICE AT 336-889-4871.
Mar 27, 2007
CERTAIN MY 1994 THROUGH 2002 THOMAS BUILT MINOTOUR, FS-65, MVP-EF, ER, AND HDX-EF SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 23, 1994, AND APRIL 15, 2002. THE SEAT BELT MAY CHAFE ON THE EDGE OF A METAL BRACKET AND WEAR PREMATURELY.
Consequence & remedy
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, POSSIBLY RESULTING IN PERSONAL INJURY.
Remedy: THOMAS BUILT WILL NOTIFY OWNERS AND REPLACE ANY CHAFED SEAT BELTS AND REPLACE OR MODIFY THE RETAINER STRIP TO PREVENT ANY FURTHER CHAFING. THE RECALL BEGAN ON FEBRUARY 8, 2008. OWNERS MAY CONTACT THOMAS BUILT AT 336-889-4871 OR CONTACT FREIGHTLINER AT 800-547-0712.
Apr 27, 2005
CERTAIN 1998-2003 MY FREIGHTLINER FS-65 SCHOOL BUS CHASSIS AND MB-45, MB-55, AND XB SHUTTLE BUS CHASSIS, AND THOMAS BUILT BUS: MVP-ER AND MVP-EF SCHOOL BUS AND NON-SCHOOL BUS MODELS EQUIPPED WITH CUMMINS ISB DIESEL ENGINES AND EQUIPPED WITH FEDERAL-MOGAL 12 AND 24 VOLT FUEL LIFT PUMPS. THE FUEL PUMP COULD FAIL TO TRANSFER FUEL APPROPRIATELY CREATING AN ENGINE STALL CONDITION.
Consequence & remedy
Consequence: SHOULD THE ENGINE STALL WHILE THE VEHICLE IS IN USE, A POSSIBLE VEHICLE CRASH COULD OCCUR.
Remedy: CUMMINS WILL NOTIFY THE CUSTOMERS OF FREIGHTLINER AND THOMAS BUILT AND REPLACE THE FUEL LIFT PUMP FREE OF CHARGE. OWNERS MAY CONTACT CUMMINS AT 1-800-DIESELS.
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).
Jun 2, 2003
ON CERTAIN THOMAS SCHOOL BUSES, THE ALTERNATOR CABLE CAN PINCH BETWEEN THE AIR CONDITIONING COMPRESSOR AND ENGINE BLOCK.
Consequence & remedy
Consequence: THIS CAN RESULT IN DAMAGE TO WIRE INSULATION AND POTENTIALLY CAUSE A SHORT CIRCUIT.
Remedy: DEALERS WILL RE-ROUTE THE CABLE. OWNER NOTIFICATION BEGAN JULY 28, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FREIGHTLINER/THOMAS BUILT AT
Oct 31, 2002
ON CERTAIN SCHOOL OR TRANSIT BUSES WITH PASSENGER SEAT BELTS WITH RETRACTORS, THE COVER HALVES FOR THE RETRACTABLE PORTION OF THE BELT CAN SEPARATE COMPLETELY AND RELEASE THE SEAT BELT CONNECTOR. IF THIS OCCURS, ONE OF THE LOAD BEARING PINS IN THE CONNECTOR COULD SEPARATE FROM THE CONNECTOR AND RENDER THE SEAT BELT UNUSABLE. IN THE EVENT OF A CRASH, THE SEAT OCCUPANT WOULD NOT BE PROPERLY RESTRAINED RESULTING IN AN INJURY. THE SEAT BELT SUPPLIER, AMSAFE, WILL PROVIDE A SNAP ON "OVER-COVER" TO OWNERS TO PREVENT THE SEAT BELT COVER FROM SEPARATING.
Consequence & remedy
Consequence: IF THIS OCCURS, ONE OF THE LOAD BEARING PINS IN THE CONNECTOR COULD SEPARATE FROM THE CONNECTOR AND RENDER THE SEAT BELT UNUSABLE. IN THE EVENT OF A CRASH, THE SEAT OCCUPANT WOULD NOT BE PROPERLY RESTRAINED RESULTING IN AN INJURY.
Remedy: DEALERS WILL PROVIDE A PLASTIC OUTER COVER THAT SNAPS OVER THE EXISTING COVER ON UNITS IN THE FIELD AND WILL REPLACE BROKEN SEAT BELTS FREE OF CHARGE. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 336-841-5924 OR AMSAFE AT 574-266-8330.
Aug 6, 2002
ON CERTAIN SCHOOL AND TRANSIT BUSES, THE WHEEL LUG NUT MAY NOT TIGHTEN COMPLETELY.
Consequence & remedy
Consequence: THE WHEEL COULD LOOSEN INCREASING THE RISK OF LOSS OF CONTROL OF THE VEHICLE.
Remedy: DEALERS WILL INSTALL NEW WHEEL STUDS. OWNER NOTIFICATION BEGAN FEBRUARY 28, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 336-889-4871.
Dec 12, 2001
VEHICLE DESCRIPTION: CERTAIN SCHOOL BUSES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 217, "BUS EMERGENCY EXITS AND WINDOW RETENTION AND RELEASE." A THIRD ROOF HATCH MUST BE ADDED TO MEET THE STANDARD REQUIREMENTS. ONLY VEHICLES LOCATED IN THE STATE OF WASHINGTON ARE INVOLVED.
Consequence & remedy
Consequence: IN THE EVENT OF A CRASH, THE BUS OCCUPANT MAY NOT BE ABLE TO EXIT THE BUS QUICKLY.
Remedy: DEALERS WILL INSTALL A THIRD ROOF HATCH. OWNER NOTIFICATION BEGAN MAY 1, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 336-889-4871.
Nov 1, 2001
VEHICLE DESCRIPTION: CERTAIN SCHOOL BUSES EQUIPPED WITH SYNTEC SEATS FAIL TO CONFORM TO THE REQUIREMENTS OF FMVSS NO. 222, "SCHOOL BUS PASSENGER SEATING AND CRASH PROTECTION." SOME SEATS (1) FAIL TO MEET THE REQUIRED FOUR INCH CLEARANCE DURING THE TEST PROCEDURE, WHILE STILL MEETING THE POST TEST CONDITION; (2) FAIL TO MEET THE REQUIRED FRONTAL PRE-LOAD WHEN TESTING UNDER CERTAIN CONDITIONS; OR (3) WHILE STILL MEETING THE REQUIRED FORCE/DEFECTION, EXPERIENCE WELD BREAKAGE.
Consequence & remedy
Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY PROTECTED.
Remedy: DEALERS WILL REPLACE THE SEAT FRAME AND THE SEAT BACK CUSHION ON THESE VEHICLES. OWNER NOTIFICATION BEGAN NOVEMBER 13, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 336-889-4871.
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
3PE07054 · 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.
PE04062 · Tie Rod Tube Failure
Opened Sep 3, 2004 · Closed Feb 2, 2005
Status: closed (inferred from source dates) · Steering:linkages:tie Rod Assembly
THIS INVESTIGATION WAS PROMPTED BY COMPLAINTS FROM TWO SEPARATE SCHOOL BUSFLEETS.BOTH FLEETS ALLEGED THAT WHILE MANEUVERING IN A PARKING AREA, THE TIE-ROD TUBE DISCONNECTED FROM ONE OF THE TIE-RODS.DANA, FREIGHTLINER AND THOMAS BUILT BUSES RECENTLY COMPLETED EXTENSIVE TESING AND DETERMINED THAT A CRACK MAY INITIATE ON THE INTERNAL THREAD ROOT OF THE TIE ROD.THIS CONDITION IS DUE TO INADEQUATE DAMPENING IN THE CHASSIS SYSTEM TO ACCOUNT FOR NORMAL BRAKE-INDUCED VIBRATION.THESE CRACKS MAY LEAD TO SEPARATION OF THE TIE ROD FROM THE ASSEMBLY.APPROXIMATELY 5,839 DANA STEER AXLES EQUIPPED WITH A CERTAIN TRW TIE ROD ASSEMBLY UTILIZING A CUT THREAD DESIGN ARE INVOLVED:A.1320 AXLE APPLICATIONS, THOMAS PART NUMBER 61110702 AND 61110705 INSTALLED ON THOMAS BUSES WITH 6" BRAKES AND 30" AIR CHAMBERS;B.1460 AXLE APPLICATIONS, THOMAS BUS PART NUMBER 61110707 AND 61110708 INSTALLED WITH 6" BRAKES AND 30" AIR CHAMBERS. THOMAS BUILT BUS WILL REPLACE THE EXISTING TIE ROD ASSEMBLIES WHICH CONTAIN THE CUT THREAD DESIGN WITH A NEW TIE ROD ASSEMBLY THAT UTILIZES A ROLLED THREAD DESIGN.A ROLLED THREAD PROVIDES LESS STRESS ON THE CRITICAL AREA OF THE TIE ROD. A COPY OF THE DEFECT REPORT IS ATTACHED. THIS ACTION RESOLVES THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY,THIS INVESTIGATION IS CLOSED.
EA04014 · School Bus Lighting Failures
Opened Jun 9, 2004 · Closed Dec 20, 2004
Status: closed (inferred from source dates) · Exterior Lighting:headlights:switch; Interior Lighting
SEE ATTACHED FOUR PAGE TECHNICAL REPORT FOR DETAILS.
Additional source detail variants (2)
Exterior Lighting:headlights:switch
SEE ATTACHED FOUR PAGE TECHNICAL REPORT FOR DETAILS.
Interior Lighting
SEE ATTACHED FOUR PAGE TECHNICAL REPORT FOR DETAILS.
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