2025 THOMAS BUILT BUSES SAF-T-LINER C2

11 recalls — 0 complaints

EXTERIOR LIGHTING:HAZARD FLASHING WARNING LIGHTS

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain Thomas Built Buses 2024-2027 Saf-T-Liner C2 school buses. The vehicle's software may misinterpret contact if the door switch is bumped, deactivating the amber and red warning lights and the stop sign arm.

Consequence

Warning lights and a stop sign arm that fail to activate will not warn other drivers the school bus is slowing down, increasing the risk of a crash or injury.

Remedy

Dealers will update the amber and red warning light software, free of charge. Owner notification letters are expected to be mailed June 8, 2026. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is F1032.

3,285 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

SERVICE BRAKES, AIR:DISC:CALIPER

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain Thomas Built Buses 2025-2026 Saf-T-Liner C2 and Saf-T-Liner C2 Jouley school buses. The brake caliper mounting bolts may loosen and detach, which can cause a loss of brake function and damage the tire and/or wheel.

Consequence

A loss of brake function can increase the risk of a crash. In addition, a damaged wheel or tire can lead to a loss of vehicle control, increasing the risk of a crash.

Remedy

Dealers will inspect and replace or tighten the brake caliper mounting bolts, as necessary, free of charge. Owner notification letters were mailed November 10, 2025. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is F1023.

36 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STEERING:LINKAGES:TIE ROD ASSEMBLY

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain Thomas Built Buses 2025-2026 Saf-T-Liner HDX, Saf-T-Liner C2, 2026 Saf-T-Liner EFX, and Saf-T-Liner C2 Jouley school buses. The tie rod castle nut and cotter pin may not be installed properly, which can result in a loss of vehicle steerin... Read more

Consequence

A loss of vehicle steering control increases the risk of a crash.

Remedy

Dealers will inspect and replace the tie rod assembly, as necessary, free of charge. Owner notification letters were mailed November 10, 2025. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is D25R2.

99 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

ELECTRICAL SYSTEM:WIRING

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain Thomas Built Buses 2025 Saf-T-Liner C2 transit buses. The ground cable for the air conditioning system may have been improperly installed and overheat.

Consequence

An overheated ground cable can increase the risk of a fire.

Remedy

Dealers will inspect and repair the ground cable connection, free of charge. Owner notification letters were mailed September 11, 2024. Owners may contact DTNA customer service at 800-745-8000. DTNA's number for this recall is F1008.

13 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

ELECTRICAL SYSTEM:WIRING

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain Thomas Built Buses 2024-2025 Saf-T-Liner C2 and Saf-T-Liner C2 Jouley school buses. The ground cable for the air conditioning system may have been improperly installed and overheat.

Consequence

An overheated ground cable can increase the risk of a fire.

Remedy

629 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STRUCTURE:EMERGENCY:ESCAPE/EGRESS/EXIT

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2023-2025 Thomas Built Buses Saf-T-Liner C2 and 2024-2025 Thomas Built Buses Saf-T-Liner C2 Jouley school buses. The audible emergency warning alarm sounds may not activate when the emergency hatch or window is open. As such, these vehi... Read more

Consequence

An inaudible alarm that fails to warn the driver of an open emergency exit can increase the risk of injury in a crash.

Remedy

Dealers will update the emergency sound software, free of charge. Owner notification letters were mailed August 22, 2024. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is F1004.

162 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STEERING:LINKAGES:TIE ROD ASSEMBLY

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2024-2025 Thomas Built Buses Saf-T-Liner C2 and 2025 Thomas Built Buses Safe-T-Liner EFX school buses. The front axle tie rod ball joint studs may crack and break, which can result in tie rod separation.

Consequence

Tie rod separation can cause a sudden loss of steering control and increase the risk of a crash.

Remedy

Dealers will replace the tie rod assembly, free of charge. Owner notification letters were mailed July 25, 2024. Owners may contact DTNA customer service at 800-745-8000. DTNA's number for this recall is D24R6.

27 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

WHEELS:HUB

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2025 Thomas Built Buses Saf-T-Liner C2 and EFX school buses. The wheel hub fasteners may loosen and cause the wheel to detach, which can result in a loss of vehicle control.

Consequence

A loss of vehicle control increases the risk of a crash.

Remedy

Dealers will inspect and replace the hub nut retaining system, wheel end, and axle components, as necessary free of charge. Owner notification letters were mailed July 18, 2024. Owners may contact DTNA customer service at 800-745-8000. DTNA's number for this recall is F1002.

106 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

WHEELS:HUB

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2025 Freightliner Custom Chassis MC, MT45, MT45G, MT55, S2C 106, S2RV 106, XBS, XCM, XCP, XCR, XCS, Freightliner 108SD, 114SD, Business Class M2, Western Star 47X, 49X, 57X, and Thomas Built Buses Saf-T-Liner C2 transit buses, cabs, and c... Read more

Consequence

A loss of vehicle control increases the risk of a crash.

Remedy

285 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

PARKING BRAKE

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2024-2025 Thomas Built SAF-T-Liner C2 and SAF-T-Liner C2 Jouley school buses. The rubber ball seal in the Intellipark Park Valve Modules (PVM) may fracture and cause a leak, which can result in park brake failure or unexpected park brake... Read more

Consequence

Park brake failure or unexpected park brake engagement while driving increases the risk of a crash.

Remedy

Dealers will replace the Intellipark PVM, free of charge. Owner notification letters were mailed August 2, 2024. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is F1000.

398 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

STRUCTURE:BODY

Defect Description

Daimler Trucks North America, LLC (DTNA) is recalling certain 2024-2025 Thomas Built SAF-T-LINER C2 and 2024 Thomas Built SAF-T-LINER C2 Jouley school buses. A rear interior joint between the bulkhead and window panel may have been manufactured incorrectly, resulting in insufficient joint strength.... 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 mechanical fasteners to secure the joints, free of charge. Owner notification letters were mailed January 26, 2024. Owners may contact DTNA customer service at 1-800-547-0712. DTNA's number for this recall is FL986.

321 vehicles affected

Manufacturer: Daimler Trucks North America, LLC

No complaints found for this vehicle.

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 (current)	11	0
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	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