2001 THOMAS BUILT BUSES SAF-T-LINER C2

1 recalls — 0 complaints — 154 TSBs

STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

Defect Description

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 RO... Read more

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. O... Read more

243,435 vehicles affected

Manufacturer: DAIMLER TRUCKS NORTH AMERICA

No complaints found for this vehicle.

Technical Service Bulletins — 2001 THOMAS BUILT BUSES SAF-T-LINER C2

154 manufacturer communications from 126 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL	43
350000 EQUIPMENT	25
110000 ELECTRICAL SYSTEM	9
060000 ENGINE AND ENGINE COOLING	9
060000 ENGINE (PWS)	8
100000 POWER TRAIN	6
070000 FUEL SYSTEM, GASOLINE	5
090000 FUEL SYSTEM, OTHER	4

060000 ENGINE AND ENGINE COOLING

Revised Technical Service Letter for Series 60 and Series 50 Camshaft Timing Specifications. Camshaft timing, valve lash, injector height, and Jake Brake lash are all very important specifications that must be followed closely in order to o

100000 POWER TRAIN

Thomas Built Buses Service Bulletin for Axle Flange Gasket Replaced with O-Ring. Daimler Trucks North America has released a new axle shaft to hub rubber O-ring (part number 11-30728-000) as a replacement for the paper gasket (part number 1

110000 ELECTRICAL SYSTEM

Thomas Built Buses Product Awareness Bulletin on RH 3 POS Switch for Electric Operated Entrance Door

162300 STRUCTURE:BODY:DOOR

Thomas Built Buses Product Awareness Bulletin on RH 3 POS Switch for Electric Operated Entrance Door

170000 LATCHES/LOCKS/LINKAGES

Thomas Built Buses Product Awareness Bulletin on RH 3 POS Switch for Electric Operated Entrance Door

110000 ELECTRICAL SYSTEM

Thomas Built Bus Service Bulletin for When troubleshooting powernet issues, use the BCT-460DTNA PowerNet Assessment Tool. As of May 29, 2018, the AutoMeter??A? is the only Daimler-approved tool for troubleshooting vehicle powernet issues.

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Lettering Changes - Notification

040000 SERVICE BRAKES, AIR

Thomas Built Buses Product Awareness Bulletin on Axial Mounted Air Disc Brake Caliper for Saf-T-Liner C2

045000 SERVICE BRAKES, AIR:DISC

Thomas Built Buses Product Awareness Bulletin on Axial Mounted Air Disc Brake Caliper for Saf-T-Liner C2

190000 TIRES

Thomas Built Buses Product Awareness Bulletin on Hankook DH37 Drive Tire/ Spare Tire

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Heater Hose Changes

356000 EQUIPMENT ADAPTIVE/MOBILITY

Thomas Built Buses Product Awareness Bulletin on Heater Hose Changes

220000 SEATS

Thomas Built Buses Product Awareness Bulletin on National Drivera??s Seat Update

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Jouley Warranty Update

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Product Awareness Bulletin on MY2020 DD5 Engine Updates

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Defender Composite Stop Arm Changes

280000 BACK OVER PREVENTION

Thomas Built Buses Product Awareness Bulletin on C2 Backup Camera Package Changes

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Product Awareness Bulletin on Buy America Cummins B6.7 Engine

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Roof Top Lettering (Addendum)

110000 ELECTRICAL SYSTEM

Thomas Built Buses Product Awareness Bulletin on 12V Outlets Update

200000 WHEELS

Thomas Built Buses Product Awareness Bulletin on Alcoa Wheel Update a?? C2

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Defender Electric Crossing Arm

251000 ELECTRONIC STABILITY CONTROL:AUTOMATIC (ASC)

Thomas Built Buses Product Awareness Bulletin on ESC on C2 with PSI LPG Engine and Hydraulic Brakes

110000 ELECTRICAL SYSTEM

Thomas Built Buses Product Awareness Bulletin on Power Outlet

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Power Outlet

170000 LATCHES/LOCKS/LINKAGES

Thomas Built Buses Product Awareness Bulletin on Auto Reversing Door Update ??A?A? C2

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Data Book Update

251000 ELECTRONIC STABILITY CONTROL:AUTOMATIC (ASC)

Thomas Built Buses Product Awareness Bulletin on LPG Update

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Lettering Update

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Product Awareness Bulletin on DD5 Piston Standardization

100000 POWER TRAIN

Thomas Built Buses Product Awareness Bulletin on Allison 7 Year Warranty

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Product Awareness Bulletin on Cummins 6.7L Update - Radiator

110000 ELECTRICAL SYSTEM

Thomas Built Buses Product Awareness Bulletin on Alternator Update a?? C2

220000 SEATS

Thomas Built Buses Product Awareness Bulletin on Freedman Seating Update

170000 LATCHES/LOCKS/LINKAGES

Thomas Built Buses Product Awareness Bulletin on Suspension Auto-Reversing Door

020000 SUSPENSION

Thomas Built Buses Product Awareness Bulletin on Hendrickson Tapered Leaf Springs

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Slide a?? n Click Update

130000 VISIBILITY

Thomas Built Buses Product Awareness Bulletin on Next Generation PV360

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Next Generation PV360

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on New Standard C2 Black Grille

100000 POWER TRAIN

Thomas Built Buses Product Awareness Bulletin on Allison 2550 PTS w/ Detroit Engine (DD5)

160000 STRUCTURE

Service Bulletin-sb60163 Adding Floor Support for Vehicles with Automatic or Automated Transmissions

110000 ELECTRICAL SYSTEM

sbt54025 Powernet Troubleshooting Guide Batteries, Path, Alternator, and Starter

180000 VEHICLE SPEED CONTROL

sbt54024 ICU Odometer Programming

130000 VISIBILITY

SS:1034175 TBB Removing Window Stops from Passenger Windows

350000 EQUIPMENT

Reminder: Paper Service Bulletin Mailings Are Discontinued

350000 EQUIPMENT

Service Bulletin Paper Copy Mailings Are Discontinued

350000 EQUIPMENT

Service Bulletin Paper Copy Mailings Are Discontinued

350000 EQUIPMENT

Service Information Bulletin- Oil Present at the Turbocharger Compressor Housing

060000 ENGINE (PWS)

Service Information Bulletin- Oil Present at the Turbocharger Compressor Housing

080000 FUEL SYSTEM, DIESEL

Service Information Bulletin

350000 EQUIPMENT

Service Information Bulletin

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Service Information Bulletin

070000 FUEL SYSTEM, GASOLINE

Service Information Bulletin- Exhaust Gas Recirculation Crossover Pipe

356000 EQUIPMENT ADAPTIVE/MOBILITY

Service Information Bulletin- Exhaust Gas Recirculation Crossover Pipe

060000 ENGINE (PWS)

Service Information Bulletin- Exhaust Gas Recirculation Crossover Pipe

114000 ELECTRICAL SYSTEM:WIRING

Service Solution: 1033979 TBB Main Harness wiring improvement Recall

114000 ELECTRICAL SYSTEM:WIRING

Service Solution: 1033979 TBB Main Harness wiring improvement Recall

162800 STRUCTURE:BODY:HOOD

A new design for the S2 grille went into prduction on February 5, 2018. The hood design has also changed slightly to accommodate a different grille fastening strategy. The old grille and hood part part numbers will no longer be produced, an

350000 EQUIPMENT

sbt88001 New Grille Design

350000 EQUIPMENT

Technical Publications Ordering

350000 EQUIPMENT

Technical Publications Ordering

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Technical Publications Ordering

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

This bulletin provides information for air cleaner element inspection and replacement, as well as, air intake seal installation and leak check.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Required Tools for Warrantable Repair_C2 13-04R4

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

16-011 New Detroit Camshaft Housing Seal Standard Repair Time

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

New Detroit Bearing Failure Analysis Standard Diagnostic Time

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

16-009R_OWL Enhancements

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Canadian Warranty Parts Return Address Change

358100 EQUIPMENT:EMERGENCY:ESCAPE/EGRESS/EXIT

FL685 TBB Emergency Door Handles

162300 STRUCTURE:BODY:DOOR

TBB Emergency Door Handles On certain buses, the stem which joins the outside emergency door handle to the door opening mechanism may corrode. Excessive material loss of the stem due to corrosion could result in the outside handle separa

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

_Warranty Recognition Program - Coming Soon

060000 ENGINE AND ENGINE COOLING

15-028 New Detroit Coolant Line SRTs

162310 STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

OlFL685 TBB Interim-CAN TBB Emergency Door Handles

160000 STRUCTURE

OlFL685 TBB Interim-US TBB Emergency Door Handles

350000 EQUIPMENT

sbt5421 Nexiq USB-Link Upgrade and Diagnostic Connector

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

15CSA9 Release of DiagnosticLink? 8.02

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

15CSA10 The Detroit CSC announcing a new feature ? Ability to attach files to an existing CSC

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

15-013-DLR TBB Cummins 10 percent Handling Allowance

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

15CSA4 Holiday Schedule for the Detroit Customer Support Center

073100 FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:FUEL RAIL

15TL6 W470589129100 ? HDEP HP Fuel Rail Test Caps

070000 FUEL SYSTEM, GASOLINE

15-010-DLR Transmission Cooler Line Photos

100000 POWER TRAIN

15-010-DLR Transmission Cooler Line Photos

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

15-009 New Detroit Standard Diagnostic Times

060000 ENGINE (PWS)

15-009 New Detroit Standard Diagnostic Times

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

15TL5 DAVCO Shop Pro? FXP 95

072100 FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

15TL4 W470589050900 ? 3/8? Drive GEN2 Two-Stage Valve Socket

092100 FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP

15TL4 W470589050900 ? 3/8? Drive GEN2 Two-Stage Valve Socket

110000 ELECTRICAL SYSTEM

sbt5420 Guidelines for Repairing or Replacing an Electrical Harness

110000 ELECTRICAL SYSTEM

sbt5420 Guidelines for Repairing or Replacing an Electrical Harness

111000 ELECTRICAL SYSTEM:12V/24V/48V BATTERY

sbt5410 Replacing Battery Drawer Slides

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

14-036-DLR DTNA & JAD Highlights - Q3

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

14-038 Additional Detroit Standard Repair Times

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

14-039 New Detroit Standard Diagnostic Times

060000 ENGINE (PWS)

14-040 Additional Detroit CLOs for the Heavy Duty Engine Platform

060000 ENGINE (PWS)

14-040_Additional_CLOs Additional Detroit CLOs for the Heavy Duty Engine Platform

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

14-039_additional_SDTs New Detroit Standard Diagnostic Times

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

14-038_New_SRTs Additional Detroit Standard Repair Times.

Showing 100 of 154 bulletins.

NHTSA Safety Investigations — THOMAS BUILT BUSES SAF-T-LINER C2

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

PE — Closed — Model Year: 2008

Rear Leaf Spring Fractures

On June 18, 2019, the Office of Defects Investigation (ODI) opened PE19-007 to investigate instances of leaf-style suspension springs fracturing in various model 2008-2018 Thomas Built Buses (TBB) school buses, which could lead to a road hazard if a piece of the leaf spring detaches from the vehicle... while driving. This investigation was prompted by ODI’s review of field reports in Daimler Truck North America's (DTNA) Early Warning Reporting (EWR) data, describing cracked rear leaf-style suspension springs in Thomas Built school buses. ODI contacted three municipal school bus fleets with subject vehicles. These fleets described similar failures where a fractured piece of leaf spring separated from the vehicle while driving. In addition, ODI contacted a nationwide school bus transportation service provider who identified several failures of this component. DTNA’s response to NHTSA’s Information Request (IR) in this investigation acknowledged that TBB school bus leaf springs may corrode and fracture. DTNA data provided in response to the IR did not show a high frequency of failures that result in portions of a cracked leaf spring detaching from the vehicle.In the response, the majority of the information concerned C2 springs. While the C2 represents approximately 71% of the sales, 136 of 141 warranty claims (97%) were for C2 buses, and 94% of all of the replacement parts sales were for C2 springs. In 2021, DTNA retained Exponent to assess reports of rear leaf spring fractures on TBB C2 school buses. As part of its assessment, Exponent inspected in-service buses and leaf springs, conducted material and metallurgical analyses of exemplar leaf springs, and analyzed manufacturer- and fleet-generated claims data. Exponent concluded based on its assessment that DTNA’s leaf springs are typical for the industry and within DTNA’s specification, and it found a low frequency of a cracked leaf springs detaching from vehicles. Exponent also asserted that it could not confirm any instance of detachment while driving, resulting in roadway debris. In 2022, in response to NHTSA’s ongoing investigation, Exponent conducted additional analysis of the metallurgical characteristics of new and used (in-service) subject leaf springs and reviewed data from a major nationwide school bus transportation provider that had obtained leaf spring replacements. Similar to its initial findings, Exponent determined that the leaf spring material specified by DTNA is commonly used for leaf springs and adheres to industry-adopted standards. Exponent’s metallurgical analysis also showed that DTNA’s springs are coated with a corrosion inhibitor. Exponent’s failure analysis of fractured leaf springs found that the fractures were due to fatigue crack initiation and growth, a common fracture mode for this component. Exponent’s inspection of in-service leaf springs found surface corrosion within the expected range. Exponent also found that corrosion pitting may play a role in fatigue crack initiation. Exponent’s analysis of DTNA warranty data found one claim in which part of the leaf spring was described as missing. Based on NHTSA’s investigation, including its careful review and assessment of the analysis provided by DTNA’s consultant Exponent, there is insufficient information at this time to conclude that a defect results in detached leaf springs creating a hazard for other roadway users. However, ODI does acknowledge that most roadway users encountering this type of debris would not know what it was or where it came from. For reporting purposes, using roadway debris as a measure could result in this issue being under-reported. Additionally, leaf springs are generally considered wear components that need routine inspection. If signs of corrosion or fracture are present, leaf springs should be immediately replaced. During NHTSA’s investigation, DTNA did share messaging with school bus fleets reminding them of the importance of routine and required inspection of school bus wear components, including leaf springs. Considering the nature of this component and available information, including the metallurgical analysis of DTNA’s in-use components and low rate of broken or missing leaf springs for the subject population, this Preliminary Evaluation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety‐related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances.Read more

PE — Closed — Model Year: 2013

Blocked Fuel Delivery Resulting in Stall

ODI was made aware of multiple allegations of engine stall resulting from a loose barcode sticker in the fuel tank of certain model year (MY) 2012 Thomas Built Saf-T-Liner transit style buses manufactured by Thomas Built Buses, Inc. (TBB).The loose barcode sticker from a diesel powered cab heater (i... Read more

PE — Closed — Model Year: 2008

Inoperative 8-Way Warning Lamps

This investigation was opened after ODI received a complaint from a school bus fleet stating they had experienced warning lamps failing upon opening the front entrance door. After completing their evaluation, Daimler Trucks North America, the parent company of Freightliner and Thomas Built Buses, de... Read more

PE — Closed — Model Year: 2008

REAR SPRING TRAILING ARM BOLT LOOSE

THIS INVESTIGATION WAS OPENED AFTER ODI WAS INFORMED BY TWO SCHOOL BUS FLEETS THAT THEY HAD FOUND LOOSE BOLTS ON THE REAR SUSPENSION TRAILING ARMS OF THE AIR RIDE SUSPENSION ON SEVERAL OF THEIR BUSES. ODI VISITED THE LOCAL DEALER AND CONFIRMED THE LOOSE BOLTS.IF THESE BOLTS FAIL AND SEPARATE, THE RE... Read more

PE — Closed — Model Year: 2008

DOOR GLASS DETACHMENT

THIS INVESTIGATION WAS OPENED AFTER A FLEET NOTIFIED ODI THAT IT HAD LOST A FRONT DOOR GLASS PANEL WHILE THE BUS WAS BEING OPERATED.A FIELD INSPECTION REVEALED TWELVE MORE BUSES HAD LOOSE DOOR GLASS PANELS.ODI IS ALWAYS CONCERNED WITH OBJECTS THAT SEPARATE FROM VEHICLES AND COULD POSSIBLY STRIKE ANO... Read more

PE — Closed — Model Year: 2005

IMPROPER HANDRAIL INSTALLATION

THIS INVESTIGATION WAS OPENED AFTERA SCHOOL BUS DISTRICT INFORMED ODI THAT DURING A NEW BUSINSPECTION THE HANDRAILS WERE FOUND TO BE MOUNTED TOO CLOSE TO THE BOTTOM STEP OF THE BUS AND FAILED THE DRAWSTRING TEST.(THE DRAWSTRING TEST WAS DEVELOPED IN THE EARLY 90'S TO ENSURE THAT CHILDREN'S DRAWSTRIN... Read more

PE — Closed — Model Year: 2005

INADVERTENT DOOR CLOSING

THIS INVESTIGATION WAS OPENED BASED ON FOUR FLEETS CONTACTING ODI ALLEGING MULTIPLE EVENTS WHERE THE FRONT ENTRANCE DOOR UNEXPECTEDLY CLOSED WHILE LOADING AND DISCHARGING CHILDREN.WHEN THIS OCCURS, THE BUS WARNING LIGHTS (RED WARNING LAMPS AND STOP ARM LAMPS) ARE DE-ACTIVATED, SINCE THEY OPERATE OFF... Read more

THOMAS BUILT BUSES SAF-T-LINER C2 — All Years Overview

Complete safety history for the THOMAS BUILT BUSES SAF-T-LINER C2 across all model years (1995–2027).

430 Total Recalls

25 Total Complaints

7 Investigations

1 Reported Crashes

1 Reported Fires

0 Reported Deaths

THOMAS BUILT BUSES SAF-T-LINER C2 — Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2027	4	0	View
2026	5	0	View
2025	11	0	View
2024	12	0	View
2023	12	0	View
2022	12	3	View
2021	15	0	View
2020	16	1	View
2019	24	0	View
2018	22	1	View
2017	28	0	View
2016	25	0	View
2015	20	2	View
2014	18	0	View
2013	18	1	View
2012	16	3	View
2011	22	0	View
2010	22	1	View
2009	21	2	View
2008	27	6	View
2007	25	1	View
2006	21	2	View
2005	16	0	View
2004	5	0	View
2003	4	1	View
2002	2	1	View
2001 (current)	1	0
2000	1	0	View
1999	1	0	View
1998	1	0	View
1997	1	0	View
1996	1	0	View
1995	1	0	View

Other THOMAS BUILT BUSES Models

Model	Recalls	Complaints
C2	0	0	View
CL-960	0	0	View
CONVENTIONAL	0	0	View
EF	0	0	View
ER	0	0	View
FS-65	0	0	View
FS65	0	0	View
HDX	0	0	View