2022 THOMAS BUILT BUSES SAF-T-LINER C2

12 recalls — 3 complaints — 116 TSBs

EQUIPMENT:OTHER:LABELS

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain Thomas Built Buses 2019-2022 Saf-T-Liner C2, Saf-T-Liner EFX, Saf-T-Liner HDX, Minotour DRW, 2020-2022 Saf-T-Liner C2 Jouley, and Minotour SRW school buses. The Emergency Exit Label lettering is too small and may be difficult to read. A... Read more

Consequence

Emergency exit labels that are difficult to read can prevent or delay the use of the emergency exit, increasing the risk of injury.

Remedy

Dealers will correct the lettering, free of charge. Owner notification letters were mailed September 5, 2024. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL918.

27,494 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STRUCTURE:EMERGENCY:ESCAPE/EGRESS/EXIT:LATCHING/RELEASE SYSTEM

Defect Description

Daimler Trucks North America, LLC. (DTNA) is recalling certain 2019-2024 Thomas Built SAF-T-LINER C2 and 2020-2024 Thomas Built SAF-T-Liner Jouley school buses. The fasteners for the emergency exit door may loosen and detach, which can allow the emergency exit door to open unexpectedly.

Consequence

An emergency exit door opening unexpectedly can increase the risk of an injury.

Remedy

Dealers will inspect and tighten the fasteners for the emergency exit door, as necessary, free of charge. Owner notification letters were mailed December 1, 2023. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL982.

20,668 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STRUCTURE:EMERGENCY:ESCAPE/EGRESS/EXIT:LATCHING/RELEASE SYSTEM

Defect Description

Daimler Trucks North America, LLC. (DTNA) is recalling certain 2019-2024 Thomas Built SAF-T-LINER C2 transit buses. The fasteners for the emergency exit door may loosen and detach, which can allow the emergency exit door to open unexpectedly.

Consequence

An emergency exit door opening unexpectedly can increase the risk of an injury.

Remedy

173 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

ELECTRICAL SYSTEM

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021-2023 Thomas Built Bus SAF-TLINER C2 JOULEY school buses equipped with an automatic low voltage disconnect switch. The automatic low voltage disconnect switch may fail, resulting in a loss of drive power, power steering, or vehicle l... Read more

Consequence

A loss of drive power, power steering, or vehicle lighting can increase the risk of a crash.

Remedy

Dealers will remove the automatic low voltage disconnect switch, free of charge. Owner notification letters were mailed October 18, 2023. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL968.

380 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STRUCTURE:BODY

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021-2024 Thomas Built SAF-T-LINER C2 and 2021-2023 Thomas Built SAF-T-LINER C2 Jouley school buses. A rear interior joint may have been manufactured incorrectly, resulting in insufficient joint strength. As such, these vehicles fail t... Read more

Consequence

A school bus with insufficient joint strength may not adequately protect passengers in the event of a crash, increasing the risk of injury.

Remedy

Dealers will add additional fasteners to secure the joints, free of charge. Owner notification letters were mailed December 19, 2023. Owners may contact DTNA customer service at 1-800-574-0712. DTNA's number for this recall is FL973.

23,590 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

ENGINE AND ENGINE COOLING:ENGINE:ENGINE CONTROL MODULE (ECU/ECM)

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2020-2023 Thomas Built C2 Saf-T-Liner school buses equipped with 8.8L LPG engines. The engine control module (ECM) may set a fault code that results in an unexpected engine shut down.

Consequence

Unexpected engine shut down can increase the risk of a crash. Additionally, a disabled school bus may require an evacuation procedure in an uncontrolled traffic situation, increasing the risk of injury to passengers.

Remedy

Dealers will update the ECM software, free of charge. Owner notification letters were mailed October 28, 2022. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL942.

461 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2022 Thomas Built Saf-T-Liner C2 school buses. The gas pedal may be misaligned and wear a hole into the floor mat, which can trap the gas pedal.

Consequence

A trapped gas pedal will not allow the vehicle to decelerate as expected when the driver lifts their foot from the gas pedal, resulting in unintended acceleration and an increased risk of a crash.

Remedy

Dealers will inspect and replace the gas pedal assembly as necessary, free of charge. Owner notification letters are expected to be mailed February 5, 2022. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL913.

1,218 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

PARKING BRAKE:ELECTRICAL:SWITCH

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021-2022 Thomas Built C2 Saf-T-Liner school buses. The parking brake activation switch may fail to set the parking brake.

Consequence

Unintended movement of the vehicle increases the risk of a crash.

Remedy

DTNA will update the Dash Electronic Control Unit (DECU ) software, free of charge. Owner notification letters were mailed on September 14, 2021. Owners may contact DTNA's customer service at 1-800-547-0712. DTNA's number for this recall is FL-896.

267 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STEERING:LINKAGES:TIE ROD ASSEMBLY

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021-2022 Thomas Built Saf-T-Liner HDX School Buses and Saf-T-Liner C2 School Buses. The tie rod clamps may be loose, which could result in loose tie rod ends that could break or detach.

Consequence

Detached or broken tie rod ends can result in steering loss, increasing the risk of a crash.

Remedy

Dealers will replace the tie rod clamp bolts and nuts, free of charge. Owner notification letters were mailed December 23, 2021. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL-888.

479 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STEERING:LINKAGES:TIE ROD ASSEMBLY

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021-2022 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner EFX, and Saf-T-Liner HDX school buses. The steering arm and tie rod bolts may have a defective seam that can fracture.

Consequence

A fractured bolt may cause a loss of steering, increasing the risk of a crash.

Remedy

DTNA will notify owners, and dealers will replace the tie rod arm bolts and steering arm, free of charge. The recall began on June 10, 2021. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL-884.

1,252 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2022 Thomas Built Saf-T-Liner C2 school buses. The hydraulic caliper tie bar support fasteners on the steer axles may not have been properly tightened or the tie bar may have not been installed in some cases.

Consequence

A dangling tie bar could come in contact with the rotating wheel-end components or damage may occur from the brake parts flexing. Either scenario may increase the risk of a crash.

Remedy

DTNA will notify owners, and dealers will inspect both steer axle wheel-ends to make sure that the four tie bar mounting fasteners are properly tightened. If the required tie bar is missing, the caliper anchor mounts and functionality (brake pad slide pins and pad movement) will be inspected before... Read more

278 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2021 Freightliner Custom Chassis MC, Business Class M2, Custom Chassis MBC Chassis, Custom Chassis S2 Chassis, Custom Chassis MT55 Chassis, and 2022 Custom Chassis Saf-T-Liner C2 vehicles. The hydraulic caliper tie bar support fasteners ... Read more

Consequence

A dangling tie bar could come in contact with the rotating wheel-end components or damage may occur from the brake parts flexing. Either scenario may increase the risk of a crash.

Remedy

80 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

Complaint Statistics

3 total complaints

Top Reported Components

Component	Complaints
LANE DEPARTURE: BLIND SPOT DETECTION	1
VISIBILITY	1
VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR	1

Incident date: Aug 18, 2021

This is a preventative complaint. In my opinion, all the Thomas Saf-T-Liner C2 school buses have a serious blind spot due to the location of the driver's side mirrors. When pulling up to an intersection, or stop sign, the driver has to bend forward and backward to see past the mirror for oncoming tr... Read more

Incident date: Aug 18, 2021

Technical Service Bulletins — 2022 THOMAS BUILT BUSES SAF-T-LINER C2

116 manufacturer communications from 84 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
350000 EQUIPMENT	23
060000 ENGINE AND ENGINE COOLING	21
110000 ELECTRICAL SYSTEM	15
200000 WHEELS	6
120000 EXTERIOR LIGHTING	5
980000 UNKNOWN OR OTHER	5
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL	4
170000 LATCHES/LOCKS/LINKAGES	4

060000 ENGINE AND ENGINE COOLING

Revised Emissions Recall: Cummins DEF Sensor Shortage. REVISION: Some vehicles formerly in Group F have been moved to Group G and have been assigned a new part number as specified in Table 1. An SRT for 'Calibration Code Only: Update or Con

060000 ENGINE AND ENGINE COOLING

Important Campaign Information letter for FL974 - Revised Bulletin & Population

060000 ENGINE AND ENGINE COOLING

Emissions Recall: Cummins DEF Sensor Shortage

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Service Bulletin for DEF Connector Reinforcement Caps. Some customers experience separation of the diesel exhaust fluid (DEF) lines from the connection ports in extreme cold temperatures. To prevent this, a process was de

050000 PARKING BRAKE

Important Campaign Information Letter for SF633 Revised Bulletin. This letter is to inform you that a revised bulletin for Field Service SF633 FCCC School Bus Chassis Park Brake Alarm is available on DTNAConnect. REVISION: Due to a software

050000 PARKING BRAKE

Revised Field Service Campaign for FCCC School Bus Chassis Park Brake Alarm. On certain vehicles, the park brake alarm software parameter may be disabled. With a disabled park brake alarm, if the driver turns off the ignition without settin

200000 WHEELS

Product Awareness Bulletin for AUTOMATIC TIRE CHAINS DISCONTINUED

200000 WHEELS

Product Awareness Bulletin for SUSPENSION OF BF GOODRICH TIRE OPTIONS

160000 STRUCTURE

Product Awareness Bulletin for C2 Undercoating Process Review.

120000 EXTERIOR LIGHTING

Updated Product Awareness Bulletin for LED LAMP UPDATES AND OPTION CHANGES - C2

130000 VISIBILITY

Updated Product Awareness Bulletin for LED LAMP UPDATES AND OPTION CHANGES - C2

060000 ENGINE AND ENGINE COOLING

PSI 8.8L DRIVEFORCE PROPANE SUSPENDED. Effective immediately, we will suspend the PSI 8.8L Driveforce (LPG) engine option for our Saf-T-Liner C2 product. Significant supply chain constraints coupled with low production volumes of this propa

200000 WHEELS

REQUIRED TIRE CHANGES AND OPTION UPDATES a??C2/eC2. A labor strike at HankookKorea has disrupted the tire supply chain resulting in shortages that immediately impact our production. As a result, orders in our backlog configured with Hankook

200000 WHEELS

980000 UNKNOWN OR OTHER

TBB Product Awareness Bulletin for E180WM008 TBB WHITE DISCONTINUED. To further our efforts to simplify our product options and improve our manufacturing efficiency, we are immediately discontinuing our paint sales codes for BASF E180WM008

060000 ENGINE AND ENGINE COOLING

TBB Product Awareness Bulletin for WEBASTO HEATERS WITH DETROIT DD5 ENGINE. Detroit DD5 engines have introduced improved performance in both fuel efficiency and active regens. Their efficient technology has made them ideal products for many

350000 EQUIPMENT

200000 WHEELS

TBB Product Awareness Bulletin for TEMPORARY SUSPENSION OF BFG TIRE OPTIONS. We have immediately suspended our BF Goodrich tire options for Saf-T-Liner C2, HDX and EFX as a result of supply chain shortages. No time period has been provided

160000 STRUCTURE

TBB Product Awareness Bulletin for Fasteners a??Temporary Deviation. TBB is dealing with multiple Fastener supply shortages; you may notice a change of fasteners in some areas of our products. Please rest assured that engineering has develo

350000 EQUIPMENT

TBB Product Awareness Bulletin for INSTA-CHAIN SNOW AND ICE CHAINS DISCONTINUED. We are immediately discontinuing Insta-Chain Snow and Ice chain options below. Insta-Chain has been acquired by OnSpot, also a supplier of snow and ice chains.

980000 UNKNOWN OR OTHER

Product Awareness Bulletin for Canadian Exchange Rate. Canadian dealers will now have the ability to select an exchange rate scenario, via sales code, at the time of quote validation.

050000 PARKING BRAKE

Field Service Campaign for FCCC School Bus Chassis Park Brake Alarm. On certain vehicles, the park brake alarm software parameter may be disabled. With a disabled park brake alarm, if the driver turns off the ignition without setting the pa

350000 EQUIPMENT

Product Awareness Bulletin for New Standard Equipment a?? Snap In Aisle Strip. We are excited to announce our new polymer snap-in aisle strips as standard equipment for all TBB products. This new design provides a smoother, more modern fini

120000 EXTERIOR LIGHTING

Thomas Built Buses Product Awareness Bulletin on LED Marker-Turn Lamp Containment - All Products

980000 UNKNOWN OR OTHER

Thomas Built Buses Product Awareness Bulletin on HDX-EFX-C2 Dash Plate Costing Containment

060000 ENGINE AND ENGINE COOLING

Service Solution for TBB C2 with DD5 engine for low dash heat.

130000 VISIBILITY

Service Solution for TBB C2 with DD5 engine for low dash heat.

980000 UNKNOWN OR OTHER

Thomas Built Buses Product Awareness Bulletin on Vehicle Application Code Updates and Clean Idle Labels

160000 STRUCTURE

Thomas Built Buses Product Awareness Bulletin on New Rear Bumper Topcoat for all TBB Vehicles

060000 ENGINE AND ENGINE COOLING

Supply chain shortage notice. Model Year 2022 Freightliner, Western Star, Freightliner Custom Chassis, and Thomas Built Bus vehicles manufactured with the following engines have been built without a Particulate Matter (PM)/Soot sensor: ??

110000 ELECTRICAL SYSTEM

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Product Awareness Bulletin on Charge Air Cooler Pipe with Cummins Engine - C2

120000 EXTERIOR LIGHTING

Thomas Built Buses Product Awareness Bulletin on Skirt Mounted Light Changes

060000 ENGINE AND ENGINE COOLING

Warranty Information letter announcing that DTNA is increasing the Standard Diagnostic Times (SDTs) shown. The updated after treatment system (ATS) diesel exhaust fluid (DEF) pump times will be applied to repair orders opened on or after Ap

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Factory AM-FM Radio Update

060000 ENGINE AND ENGINE COOLING

Thomas Built Buses Product Awareness Bulletin on Ametek Pump Discontinuation - C2

110000 ELECTRICAL SYSTEM

Warranty Policy Letter for battery tags. DTNA determined that since adopting the AutoMeter BCT-460DTNA Powernet Assessment Tool (AutoMeter) as the required powernet system tester, not all battery tags have to be retained support Warranty-re

350000 EQUIPMENT

120000 EXTERIOR LIGHTING

Thomas Built Buses Product Awareness Bulletin on Discontinued Warning Light Packages

980000 UNKNOWN OR OTHER

Thomas Built Buses Product Awareness Bulletin on Greenhouse Gas (GHG) 2021 - Configurator Update

110000 ELECTRICAL SYSTEM

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030000 BRAKES (PWS)

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120000 EXTERIOR LIGHTING

Thomas Built Buses Product Awareness Bulletin on Stage 2 Lights for Passenger Loading-Unloading

110000 ELECTRICAL SYSTEM

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350000 EQUIPMENT

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030000 BRAKES (PWS)

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060000 ENGINE AND ENGINE COOLING

Starting on November 23, 2020, DiagnosticLink 8.13 (Build 4527) was made available. Current subscribers of DiagnosticLink 8.11 or 8.12 may upgrade to DiagnosticLink 8.13 at no cost. All DTNA Service shops & OEM locations are required to mai

050000 PARKING BRAKE

Thomas Built Buses Product Awareness Bulletin on Bendix Intellipark for Saf-T-Liner C2 PSI LPG Engine

070000 FUEL SYSTEM, GASOLINE

Customer Advisory Letter for C2 School Bus Aft Fuel System Harness Update. Freightliner Custom Chassis has determined that the aft fuel system wiring harness on C2 School Buses may not have been built as the schematic indicates. The vehicle

110000 ELECTRICAL SYSTEM

350000 EQUIPMENT

Warranty Information Letter for Body Builder/Truck Equipment Manufacturer Demonstration Program.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Warranty Information Letter for Body Builder/Truck Equipment Manufacturer Demonstration Program.

060000 ENGINE AND ENGINE COOLING

Warranty Information Letter for Detroit NOx Sensor Circuit Fault Codes - Claim Guidelines.

110000 ELECTRICAL SYSTEM

Warranty Information Letter for Detroit NOx Sensor Circuit Fault Codes - Claim Guidelines.

350000 EQUIPMENT

Warranty Information Letter for Detroit NOx Sensor Circuit Fault Codes - Claim Guidelines.

356000 EQUIPMENT ADAPTIVE/MOBILITY

Warranty Information Letter for Detroit NOx Sensor Circuit Fault Codes - Claim Guidelines.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Important Campaign Information Letter for Dealer Travel for Campaign Performance a?? TBB.

355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

Revised Warranty Information Letter for OWL and Warranty Manual Improvement: Sublets and Travel Time/Distance. In the spirit of continuous improvement, DTNA reviewed sublet-related policies and procedures. The goal was to improve language c

060000 ENGINE AND ENGINE COOLING

Customer Advisory Letter for EV School Bus Product Updates. Freightliner Custom Chassis has developed some product enhancements and improvements for certain eB2 School Busses which include software updates and adding a coolant pump mounting

110000 ELECTRICAL SYSTEM

350000 EQUIPMENT

110000 ELECTRICAL SYSTEM

Service Solution for eB2 Product Updates & Enhancements. Certain early production eB2 buses may complain of an intermittent amber colored battery light flickering or illuminating for no reason. A new software update for the EV controller ha

118000 ELECTRICAL SYSTEM:SOFTWARE

060000 ENGINE AND ENGINE COOLING

Service Solution for TBB and Freightliner EB2 Electric Bus Charging troubleshooting.

110000 ELECTRICAL SYSTEM

Service Solution for TBB and Freightliner EB2 Electric Bus Charging troubleshooting.

060000 ENGINE AND ENGINE COOLING

Warranty Information Letter for Proterra Electric Powertrain Extended Warranty on TBB Electric Vehicles and FCCC Electric School Bus Chassis. Please be aware that for TBB electric vehicles and Freightliner Custom Chassis Corporation (FCCC)

100000 POWER TRAIN

110000 ELECTRICAL SYSTEM

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

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

110000 ELECTRICAL SYSTEM

Thomas Built Buses Product Awareness Bulletin on Introducing Saf-T-Liner C2 Jouley

350000 EQUIPMENT

Thomas Built Buses Product Awareness Bulletin on Introducing Saf-T-Liner C2 Jouley

356000 EQUIPMENT ADAPTIVE/MOBILITY

Thomas Built Buses Product Awareness Bulletin on Introducing Saf-T-Liner C2 Jouley

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

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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 (current)	12	3
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	1	0	View
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