2018 Thomas Built Buses Saf-T-Liner C2 problems

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2020 Thomas Built Saf-T-Liner EFX, Minotour, Saf-T-Liner C2, and Saf-T-Liner HDX school buses equipped with SynTec S3B or S3C seats. The seats may have been manufactured with styrene blocks that may not provide sufficient impact absorption in certain specific areas around the steel seat frame of the back support. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 222, "School Bus Passenger Seating and Crash Protection."

Risk

The lack of impact absorption increases the risk of injury in the event of a crash.

Remedy

DTNA will notify owners, and dealers will install additional impact material between the re-bond back and the vinyl back cover to increase the amount of absorption, free of charge. DTNA issued owners an interim notification on November 29, 2019. The recall began June 22, 2020. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-832.

Recall number 19V712000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2020 Saf-T-Liner C2 school buses equipped with Detroit DD5 engines and Allison transmissions. The Flex-Plate/Torque Converter fasteners may have been insufficiently tightened.

Risk

The loose bolts may lead a disabled school bus and result in a school bus evacuation procedure in an uncontrolled traffic situation, increasing the risk of an injury.

Remedy

DTNA will notify owners, and dealers will inspect and tighten the fasteners, as necessary, free of charge. The recall began November 19, 2019. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-828.

Recall number 19V686000 · Recall details

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 2018-2019 Thomas Built Saf-T-Liner HDX, C2, and EFX School Buses, equipped with Detroit Axle axles. The affected vehicles may have loose steering tie rod arm bolts.

Risk

Loose tie rod arm bolts may lead to separation of the tie rod arm, affecting vehicle steering, and increasing the risk of a crash.

Remedy

DTNA has notified owners, and dealers will inspect the steering arm and tie rod arm bolts for to make sure that they are properly tightened, installing new fasteners as necessary, free of charge. The recall began February 9, 2019. Owners may contact Daimler Trucks at 1‑800‑547‑0712. DTNA's number for this recall is FL-802.

Recall number 18V914000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2019 Thomas Built Buses Saf-T-Liner C2 school buses. The roof adhesive that supports the roof header may not have been properly applied.

Risk

Improperly applied adhesive may affect the roof header joint strength, which, in the event of a rollover crash, can increase the risk of injury.

Remedy

DTNA will notify owners, and dealers will inspect the placement of the roof header adhesive, and install mechanical fasteners, as necessary, free of charge. DTNA issued owners an interim notification on February 1, 2019. The recall began March 25, 2020. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-801.

Recall number 18V877000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2019 Thomas Built Buses Saf-T-Liner C2 transit buses. The roof adhesive that supports the roof header may not have been properly applied.

Risk

Improperly applied adhesive may affect the roof header joint strength, which, in the event of a rollover crash, can increase the risk of injury.

Remedy

DTNA will notify owners, and dealers will inspect the placement of the roof header adhesive, and install mechanical fasteners, as necessary, free of charge. DTNA issued and interim notification to owners on February 1, 2019. The recall began March 25, 2020. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-801.

Recall number 18V878000 · Recall details

What is wrong

Daimler Trucks North America, LLC (DTNA) is recalling certain 2018-2019 Thomas Built school buses Saf-T-Liner C2, Saf-T-Liner HDX and Saf-T-Liner EFX school buses. The brake caliper mounting bolts may have been insufficiently tightened.

Risk

Loose brake caliper mounting bolts can reduce brake effectiveness, increasing the risk of a crash.

Remedy

DTNA has notified owners, and dealers will check and tighten the brake caliper mounting bolts, free of charge. The recall began December 3, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-794.

Recall number 18V702000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2015-2019 Thomas Built Buses Saf-T-Liner C2 and Saf-T-Liner HDX school buses, equipped with certain S-Series and K-Series Titanium Wheelchair Lifts, models K200, K201, K550, K551, S200, S2201, S550 and S551. The wheelchair lift positioning input cam may fail while the lift is in use, allowing the platform to travel higher than the vehicle's floor height.

Risk

If the wheelchair lift platform stops above the vehicle floor, the wheelchair user can tip inwards toward the vehicle when exiting the lift, increasing their risk of injury.

Remedy

Dealers will replace the injection molded cam with an aluminum machined cam, free of charge. The recall began December 6, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL785.

Recall number 18V560000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2019 Thomas Built Buses Saf-T-Liner C2 school buses, equipped with S3B 45" Restraint School Bus Seats. In the event of a crash, the seat's foot may pull through the bolted joint at the bus floor. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 210, "Seat Belt Assembly Anchorages."

Risk

In the event of a crash, if the seat detaches from the floor, it can increase the risk of injury.

Remedy

DTNA will notify owners, and dealers will install a washer between the rear mounting foot, and the bus floor to keep the seat secured, free of charge. The recall began October 17, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL787.

Recall number 18V561000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2019 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner EFX and Saf-T-Liner HDX school buses equipped with air disc brakes. The brake caliper mounting bolts on these vehicles may be insufficiently tightened, allowing the bolts to loosen.

Risk

If the brake caliper mounting bolts come loose, braking performance may be reduced, increasing the risk of a crash.

Remedy

DTNA will notify owners, and dealers will inspect the brake caliper mounting bolts and tighten them as necessary, free of charge. DTNA issued owners an interim notification on July 25, 2018. The recall began September 4, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-772.

Recall number 18V352000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2018-2019 Thomas Built Buses Saf-T-Liner C2 transit buses equipped with 2 8D batteries. The battery power cable may have inadequate clearance between the cable and the battery hold down bracket when the battery tray is pulled out for service, causing the cable to rub against the bracket.

Risk

The battery cable rubbing may cause the cable to short circuit, increasing the risk of a fire.

Remedy

DTNA will notify owners, and dealers will be inspect the battery cables and reroute them for proper clearance, as required, free of charge. Daimler issued an interim notification to owners on June 18, 2018. The recall began October 3, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL768.

Recall number 18V250000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2018 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner HDX, Saf-T-Liner EFX, and Minotour school buses equipped with S3B Restraint Wall Mounted Seats. The wall mounting bracket may crack, causing the seat to not remain secured in place in the event of a crash.

Risk

In the event of a crash, if the seat does not remain secured to the wall, the occupant has an increased risk of an injury.

Remedy

DTNA will notify owners, and dealers will install an additional wall mounting bracket, free of charge. Daimler issued owners an interim notification on June 12, 2018. The recall began January 3, 2019. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-769.

Recall number 18V253000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2018 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner EFX, Saf-T-Liner HDX, and Minotour transit buses, equipped with certain S3B Restraint Wall Mounted Seats. The wall mounting bracket may crack, causing the seat to not remain secured in place in the event of a crash.

Risk

In the event of a crash, if the seat does not remain secured to the wall, the occupant has an increased risk of an injury.

Remedy

DTNA will notify owners, and dealers will install an additional wall mounting bracket, free of charge. Daimler issued an interim notification to owners on June 15, 20 18. The recall began January 3, 2019. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-769.

Recall number 18V254000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2019 Thomas Built Buses Saf-T-Liner C2 school buses equipped with propane engines. The propane fuel line may contact the j-hook body support bracket that could cause chafing resulting in 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 clearance and reroute the line if needed. Any damaged lines will be replaced. These repairs will be performed free of charge. DTNA issued an interim notification to owners on May 9, 2018. The recall began on July 3, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-765.

Recall number 18V190000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2018 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner HDX, Saf-T-Liner EFX, and Minotour school buses, equipped with certain Syntec-brand S3B, Non-Restraint, Wall Mounted Seats. The wall mounting bracket may crack, which may cause the seat to not remain secured in place in the event of a crash.

Risk

In the event of a crash, if the seat does not remain secured to the wall, the occupant has an increased risk of an injury.

Remedy

DTNA will notify owners, and dealers will install an additional wall mounting bracket, free of charge. DTNA issued an interim notification to owners on May 9, 2018. The recall began May 10, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-763.

Recall number 18V192000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2018 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner HDX, Saf-T-Liner EFX, and Minotour transit buses, equipped with certain Syntec-brand S3B, Non-Restraint, Wall Mounted Seats. The wall mounting bracket may crack, which may cause the seat to not remain secured in place in the event of a crash.

Risk

In the event of a crash, if the seat does not remain secured to the wall, the occupant has an increased risk of an injury.

Remedy

DTNA will notify owners, and dealers will install an additional wall mounting bracket, free of charge. DTNA issued an interim notification to owners on May 10, 2018. The recall began May 10, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-763.

Recall number 18V193000 · 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 2014-2018 Thomas Built Buses Saf-T-Liner HDX and Saf-T-Liner C2 school buses. A reinforcement bracket may be missing from the seats that have 3-point seat belts.

Risk

Without the reinforcement bracket, the seat may not be adequately secured, increasing the risk of injury in a crash.

Remedy

DTNA will notify owners, and dealers will inspect the seats, installing any missing reinforcement brackets, free of charge. An interim notice was mailed to owners on November 7, 2017. The recall began on March 15, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-747.

Recall number 17V587000 · Recall details

What is wrong

Daimler Trucks North America LLC (DTNA) is recalling certain 2014-2018 Thomas Built Buses Saf-T-Liner HDX and Saf-T-Liner C2 transit buses. A reinforcement bracket may be missing from the seats that have 3-point seat belts.

Risk

Without the reinforcement bracket, the seat may not remain adequately secured, increasing the risk of injury in a crash.

Remedy

DTNA will notify owners, and dealers will inspect the seats, installing any missing reinforcement brackets, as needed, free of charge. An interim notice was sent to owners on November 7, 2017. The recall began on March 14, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-747.

Recall number 17V589000 · 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 2018 Thomas Built Buses Saf-T-Liner C2 transit buses equipped with two 8D batteries. The battery power cable may not have adequate clearance between the cable and battery hold down bracket. As a result, the cable can rub against the bracket damaging the cable.

Risk

The damaged battery cable may electrically arc, increasing the risk of a fire.

Remedy

DTNA will notify owners, and dealers will inspect the battery cable routing, rerouting it as necessary to provide the proper clearance, free of charge. DTNA issued owners an interim notification on August 6, 2018. The recall began October 3, 2018. Owners may contact DTNA customer service at 1‑800‑547‑0712. DTNA's number for this recall is FL-768.

Recall number 18V378000 · 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