2013 Thomas Built Buses Saf-T-Liner C2 problems

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2010-2020 Thomas Built Buses Saf-T-Liner C2, 2016-2019 HDX, and 2017-2019 EFX school buses equipped with Bendix Air Disc Brakes. The driver side rear brakes may drag.

Risk

The dragging brakes may lead to high temperatures at the wheel end, increasing the risk of smoke and fire, possibly resulting in the bus having to be evacuated, which can increase the risk of injury.

Remedy

DTNA will notify owners, and dealers will install a new caliper with an updated clearance adjustment mechanism, free of charge. The recall began August 9, 2019. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-818.

Recall number 19V444000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2002-2017 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner HDX, FS65, and Minotour school buses, equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit:

Risk

In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.

Remedy

DTNA will notify owners instructing them to contact Kidde for a replacement fire extinguisher, free of charge. The recall is expected to begin March 30, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712 or Kidde customer service at 1‑855‑262‑3540 or online at www.kidde.com and click on "Product Safety Recall" for more information. DTNA's number for this recall is FL-759.

Recall number 18V083000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2012-2018 Thomas Built Bus Saf-T-Liner C2 school buses. The affected vehicles are propane-powered and have propane fuel lines that may contact the transmission yoke, possibly causing a propane leak.

Risk

A propane leak in the presence of an ignition source can increase the risk of a fire.

Remedy

DTNA will notify owners, and dealers will inspect the propane line routing, correcting it as necessary, free of charge. DTNA issued owners an interim notification on December 14, 2017. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-752.

Recall number 17V665000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2005-2018 Thomas Built Buses Saf-T-Liner C2 school buses. In the event of a crash, the wheelchair pocket track anchorage may not adequately secure a the wheelchair.

Risk

In the event of a crash, an unsecured wheelchair may increase the risk of injury.

Remedy

DTNA will notify owners, and dealers will add additional fasteners to the wheelchair pocket track to reinforce the anchorage, free of charge. An interim notice was sent to owners on September 13, 2017. The recall began on December 20, 2017. Owners may contact DTNA customer service at 1‑800‑745‑8000. DTNA's number for this recall is FL-743.

Recall number 17V453000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2005-2018 Thomas Built Buses Saf-T-Liner C2 transit buses. In the event of a crash, the wheelchair pocket track anchorage may not adequately secure a the wheelchair.

Risk

In the event of a crash, an unsecured wheelchair may increase the risk of injury.

Remedy

DTNA will notify owners, and dealers will add additional fasteners to the wheelchair pocket track to reinforce the anchorage, free of charge. An interim letter was mailed on September 13, 2017. The recall began on December 20, 2017. Owners may contact DTNA customer service at 1‑800‑745‑8000. DTNA's number for this recall is FL-743.

Recall number 17V454000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain model year 1998-2002 Thomas Built Buses Saf-T-Liner Conventional, 2000-2002 Saf-T-Liner ER, 2000-2017 Saf-T-Liner MVP-EF, 1998-1999 Vista, 2003 Saf-T-Liner FS65, 2013-2017 Saf-T-liner C2, 2000-2002 Saf-T-Liner MVP-ER, 2013-2017 Saf-T-Liner HDX. In the affected vehicles, the stem that connects the outside emergency door handle to the emergency door opening mechanism may corrode.

Risk

If the stem corrodes, the door handle could detach from the emergency door opening mechanism, delaying the opening of the door and the evacuation of the bus. In the event of an emergency, this may increase the risk of injury to the bus occupants.

Remedy

DTNA will notify owners, and dealers will either replace the stems or protect them against corrosion, free of charge. An interim notice was sent to owners on July 28, 2016. A second notice was mailed to owners on December 16, 2016. Parts are available. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-713.

Recall number 16V395000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain model year 2006-2015 Thomas Built Buses FS-65, Saf-T-Liner C2, Saf-T-Liner EF, Saf-T-Liner EFX, Saf-T-Liner HDX, and Minotour DRW school buses manufactured January 3, 2006, to August 1, 2014, and equipped with certain Ricon model S2005, S2010, S5005, S5010, S5505, S5510 wheelchair lifts. The affected lifts are equipped with folding link arms that may have pivot holes that are too big, allowing the bearings to move out of position.

Risk

If the bearings move out of position, the stowed platform may have excessive movement resulting in failure of the platform mounting. This failure could cause the wheel chair lift platform to fall out of the vehicle when the doors are opened, increasing the risk of injury for the lift operator.

Remedy

DTNA will notify owners, and dealers will inspect the link arms for damage or for displaced bearings. The platform will be inspected for cracks. Any damaged parts will be replaced, free of charge. The recall began onNovember 2, 2015. Owners may contact DTNA customer service at 1‑800‑745‑8000. DTNA's number for this recall is FL-686.

Recall number 15V565000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain model year 2002-2013 Thomas Built Buses Saf-T-Liner ER, 2001-2005 Saf-T-Liner Conventional, 2002-2013 Saf-T-Liner MVP-EF, 2013 Saf-T-Liner EFX, 2001-2008 Saf-T-Liner FS65, 2005-2013 Saf-T-Liner C2, 2003-2013 Saf-T-Liner HDX, 2002-2003 Saf-T-Liner MVP-ER, 2002 Vista, and 2002-2003 TL-960 school buses manufactured from February 5, 2001, through May 29, 2012. In the affected vehicles, the stem that connects the outside emergency door handle to the emergency door opening mechanism may corrode.

Risk

If the stem corrodes, the door handle could detach from the emergency door opening mechanism, delaying the opening of the door and the evacuation of the bus. In the event of an emergency, this may increase the risk of injury to the bus occupants.

Remedy

DTNA will notify owners, and dealers will either replace the stems or protect them against corrosion, free of charge. Daimler issued an interim notification to owners on August 25, 2015. The recall began on December 24, 2015. Owners may contact DTNA customer service at 1‑800‑745‑8000. DTNA's number for this recall is FL-685.

Recall number 15V432000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain model year 2002-2004 Thomas Built Buses Saf-T-Liner ER, 2001-2005 Saf-T-Liner Conventional, 2002-2013 Saf-T-Liner MVP-EF, 2013 Saf-T-Liner EFX, 2001-2008 Saf-T-Liner FS65, 2005-2013 Saf-T-Liner C2, 2003-2013 Saf-T-Liner HDX, 2002-2003 Saf-T-Liner MVP-ER, 2002 Vista, and 2002-2003 TL-960 non-school buses. In the affected vehicles, the stem that connects the outside emergency door handle to the emergency door opening mechanism may corrode.

Risk

If the stem corrodes, the door handle could detach from the emergency door opening mechanism, delaying the opening of the door and the evacuation of the bus. In the event of an emergency, this may increase the risk of injury to the bus occupants.

Remedy

DTNA will notify owners, and dealers will either replace the stems or protect them against corrosion, free of charge. An interim notice was mailed to owners on August 28, 2015. The recall began on December 24, 2015. Owners may contact DTNA customer service at 1‑800‑745‑8000. DTNA's number for this recall is FL-685.

Recall number 15V425000 · Recall details

What is wrong

Daimler Trucks North America (DTNA) is recalling certain model year 2011-2013 Thomas Built Saf-T-Liner C2 school buses manufactured December 3, 2009, through February 8, 2012, and equipped with Eaton hybrid automated transmissions. The software controlling the affected transmissions may improperly raise the vehicle's engine speed during downshifts without the driver's input.

Risk

The increase in engine speed may result in unintended acceleration, increasing the risk of a crash.

Remedy

DTNA will notify owners and dealers will update the hybrid transmission software, free of charge. The recall began on February 5, 2014. Owners may contact DTNA at 1‑503‑745‑6910. DTNA's recall number is FL-657.

Recall number 13V633000 · Recall details

What is wrong

Daimler Trucks North America (DTNA) is recalling certain model year 2013-2015 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner HDX, and Minotour school buses manufactured August 5, 2013, through November 15, 2013 and equipped with IMMI-brand L9 seat belt buckles. When the button is pressed to release the seat belt, the latch plate can become partially engaged with the buckle, making the seat belt difficult to unlatch. Thus, these vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 209, "Seat Belt Assemblies."

Risk

If the latch plate remains partially engaged after the button is pressed, egress from the vehicle could be hindered which would increase the risk of injury in the event of an emergency.

Remedy

DTNA will notify owners, and dealers will inspect and replace the seat belt buckles, as necessary, free of charge. The recall is expected to by January 26, 2014. Owners may contact DTNA at 1‑800‑385‑4357. DTNA's number for this campaign is FL-654.

Recall number 13V606000 · Recall details

What is wrong

Daimler Trucks North America (DTNA) is recalling certain model year 2011 through 2013 Thomas Built school buses manufactured from March 2010 through July 2012, equipped with Cummins ISB6.7 diesel engines manufactured from February 16, 2010, through May 4, 2012, containing a fan pulley, part number 3914462. The subject fan pulley is part of the accessory drive system on the front of the engine. This system is used to drive such components as the refrigerant compressors, the radiator fan, and the engine water pump. The web of the pulley can fatigue over time, causing the pulley to fail.

Risk

If this occurs, the fan belt may lose engagement of the water pump, allowing the cooling system to overheat. This may result in exceeding temperature limits, potentially disabling the school bus. If the school bus is occupied when it becomes disabled, the occupants would need to exit the vehicle and be transferred to another vehicle, putting them at risk of injury.

Remedy

Cummins will notify owners of the recall. Repairs will be performed by Cummins authorized service facilities. A new fan drive pulley will be installed free of charge. The safety recall began on January 4, 2013. Owners may contact Cummins at 1‑812‑377‑5000 or DTNA at 1‑800‑547‑0712.

Recall number 12V570000 · Recall details

What is wrong

Daimler Trucks North America (DTNA) is recalling certain model year 2011 through 2013 Thomas Built non-school buses manufactured from March 2010 through July 2012, equipped with Cummins ISB6.7 diesel engines manufactured from February 16, 2010, through May 4, 2012, containing a fan pulley, part number 3914462. The subject fan pulley is part of the accessory drive system on the front of the engine. This system is used to drive such components as the refrigerant compressors, the radiator fan, and the engine water pump. The web of the pulley can fatigue over time, causing the pulley to fail.

Risk

If this occurs, the fan belt may lose engagement of the water pump, allowing the cooling system to overheat. This may result in exceeding temperature limits, potentially disabling the school bus. If the school bus is occupied when it becomes disabled, the occupants would need to exit the vehicle and be transferred to another vehicle, putting them at risk of injury.

Remedy

Cummins will notify owners of the recall. Repairs will be performed by Cummins authorized service facilities. A new fan drive pulley will be installed free of charge. The safety recall began on January 4, 2013. Owners may contact Cummins at 1‑812‑377‑5000 or DTNA at 1‑800‑547‑0712.

Recall number 12V572000 · Recall details

What is wrong

Daimler Trucks North America (DTNA) is recalling two model year 2013 Saf-T-Liner C2 Thomas Built school buses manufactured from April 18, 2012, through May 11, 2012, and equipped with Detroit Axle brand front axle knuckles. The front knuckles on these vehicles may have a machining error in the wheel bearing area which may lead to premature spindle failure.

Risk

If the spindle fails, the wheel may separate from the knuckle, resulting in loss of vehicle control, increasing the risk of a crash.

Remedy

DTNA will notify owners, and dealers will inspect and replace the affected components, free of charge. The recall began on August 10, 2012. Owners may contact Daimler Trucks North America toll free at 1‑800‑547‑0712.

Recall number 12V358000 · Recall details

What is wrong

Daimler trucks north america (dtna) is recalling certain model year 2010 through 2013 thomas built saf-t-liner ef, saf-t-liner hdx, saf-t-liner c2, and minotour school buses manufactured from april 5, 2011, through april 23, 2012, equipped with specialty manufacturing inc. (smi) prolo roof hatches. Increased friction between the rear plate assemblies, p/no. 009327, and the nylon rear pop-up support, p/no. 008956, may result in an opening force of the prolo roof hatches that exceeds federal standard requirements. Thus, these hatches fail to conform to the requirements of federal motor vehicle safety standard no. 217, "bus emergency exits and window retention and release."

Risk

In the event of an emergency, egress of the bus may be hindered possibly resulting in injury to the vehicle occupants.

Remedy

Thomas built buses will notify owners. Smi will provide service kits along with repair instructions to dealers and owners, free of charge. The safety recall began on august 22, 2012. Owners may contact thomas built buses at 1‑336‑889‑4871 or smi at 1‑800‑951‑7867.

Recall number 12V296000 · Recall details

What is wrong

Daimler trucks north america (dtna) is recalling certain model year 2010 through 2013 thomas built saf-t-liner ef, saf-t-liner hdx, saf-t-liner c2, and minotour non school buses manufactured from april 5, 2011, through april 23, 2012, equipped with specialty manufacturing inc. (smi) prolo roof hatches. Increased friction between the rear plate assemblies, p/no. 009327, and the nylon rear pop-up support, p/no. 008956, may result in an opening force of the prolo roof hatches that exceeds federal standard requirements. Thus, these hatches fail to conform to the requirements of federal motor vehicle safety standard no. 217, "bus emergency exits and window retention and release."

Risk

In the event of an emergency, egress of the bus may be hindered possibly resulting in injury to the vehicle occupants.

Remedy

Thomas built buses will notify owners. Smi will provide service kits along with repair instructions to dealers and owners, free of charge. The safety recall began on august 22, 2012. Owners may contact thomas built buses at 1‑336‑889‑4871 or smi at 1‑800‑951‑7867.

Recall number 12V297000 · Recall details

What is wrong

Daimler trucks north america (dtna) is recalling certain model year 2013 freightliner, western star, freightliner custom chassis trucks, and thomas built buses manufactured from april 18, 2012, through may 11, 2012, and equipped with detroit axle-brand front axle knuckles. The front knuckles on these vehicles may have a machining error in the wheel bearing area which may lead to premature spindle failure.

Risk

If the spindle fails, the wheel may separate from the knuckle, resulting in loss of vehicle control, increasing the risk of a crash.

Remedy

Dtna will notify owners, and dealers will inspect and replace the affected components, free of charge. The safety recall began on august 10, 2012. Owners may contact daimler trucks north america toll free at 1‑800‑547‑0712.

Recall number 12V266000 · Recall details

What is wrong

Daimler trucks (dtna) is recalling certain model year 2011 through 2013 thomas built saf-t-liner school buses built on a freightliner custom chassis b2 chassis from november 15, 2010, through october 6, 2011. The grid heater ground wire may contact the relay power terminal and rub and chafe potentially resulting in a short circuit.

Risk

An electrical fault or short circuit may result in a fire.

Remedy

Dtna will notify owners, and dealers will inspect to ensure the grid heater relay ground wire is correctly routed and modified as required to ensure adequate clearance with the power terminal. The repairs will be performed by dtna dealers free of charge. The safety recall began on february 2, 2012. Owners may contact dtna at 1‑800‑547‑0712.

Recall number 11V573000 · Recall details

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 the federal safety agency’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 the federal safety agency’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 the federal safety agency’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 the federal safety agency’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 the federal safety agency that a safety‐related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances.

PE19007

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 (installed in some cold weather state buses) may become lodged in the fuel delivery pickup tube and restrict fuel flow. Early analysis suggested that at least one failure resulted in a school bus being stranded on an interstate highway.Additionally, ODI identified 6 Early Warning Reporting (EWR) reports that appear related to the alleged defect, and TBB informed ODI that it was aware of nine (9) other related field reports for a total of fifteen (15) alleged incidents.Daimler Truck North America (DTNA), parent company of TBB, submitted a recall notice dated August 13, 2013 (13V‑365 for school buses and 13V‑364 for non-school buses) that addresses ODI's concerns.Fuel tanks will be inspected for the presence of a label.If a label is found, it will be removed from the tank.As a result of the DTNA remedial action this investigation is closed.

PE13006