Thomas SAF-T-LINER recalls by model year

Reported: 1996-07-23 (July 23, 1996) · Model years: 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

AN ITEM WORN BY A CHILD, SUCH AS A LONG DRAWSTRING, SASH, OR BACKPACK/BOOKBAG ACCESSORY, CAN BECOME CAUGHT IN THE AREA BETWEEN THE SERVICE DOOR AND THE DOOR CONTROL ROD ATTACHING BRACKET.

Consequence: IF AN ITEM WORN BY A CHILD WERE TO CATCH ON THIS AREA, AND THE DRIVER WERE TO CLOSE THE DOOR AND PUT THE VEHICLE IN MOTION, THIS CAN RESULT IN SERIOUS INJURY OR DEATH.

Remedy: A MOLDED COVER WILL BE INSTALLED BETWEEN THE MANUALLY OPERATED OUTWARD OPENING ENTRANCE DOOR AND THE DOOR CONTROL ROD ATTACHING BRACKET WHICH WILL ELIMINATE THE OPENING THAT COULD ALLOW AN ITEM OF A CHILD'S CLOTHING TO BECOME SNAGGED.

Reported: 1987-06-11 (June 11, 1987) · Model years: 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987

IN A FRONT END COLLISION, DUAL FUEL TANKS MAY SLIDE ON THE SUPPORT BRACKETS ALLOWING THE FUEL CROSSOVER PIPE END FITTINGS TO CONTACT A PIPE SUPPORT AND PROTECTION GUARD.

Consequence: THIS CONTACT MAY BREAK OR CRACK THE FITTINGS, RESULTINGIN A FUEL LEAK.

Remedy: INSTALL NEW FUEL LINE GUARD, FASTENERS AND, IF NECESSARY, A FITTING.

Reported: 1986-06-16 (June 16, 1986) · Model years: 1982, 1983, 1984, 1985, 1986

TWO THROTTLE RETURN SPRING DEFECTS ARE INVOLVED IN THIS RECALL. (1) BUSES EQUIPPED WITH CATERPILLAR ENGINES MAY HAVE A THROTTLE RETURN SPRING THAT BREAKS AND PREVENTS THE THROTTLE FROM RETURNING TO IDLE POSITION WHEN THE DRIVER'S FOOT IS REMOVED FROM THE ACCELERATOR CONTROL; (2) BUSES EQUIPPED WITH CUMMINS VT-225 ENGINES MAY HAVE THE THROTTLE RETURN SPRING CONNECTED TO THE THROTTLE SLAVE CYLINDER INSTEAD OF THE FUEL INJECTION PUMP LEVER. IF FAILURE OCCURS IN THE ACCELERATION CONTROL SYSTEM, THE ENGINE MAY ACCELERATE TO ITS MAXIMUM GOVERNED RPM. CONSEQUENCE OF DEFECT: IN EITHER CASE, THROTTLE CONTROL WILL BE LOST WHICH MAY RESULT IN AN ACCIDENT.

Remedy: A REPAIR KIT CONSISTING OF NEW SPRING, MOUNTING BRACKET AND PROPER REPAIR INSTRUCTIONS WILL BE SHIPPED TO EACH OWNER AT NO CHARGE AND THE OWNER MAY MAKE HIS OWN REPAIRS, OR HAVE A THOMAS DISTRIBUTOR OR A REPUTABLE LOCAL SHOP MAKE THE REPAIRS.

Reported: 1987-11-12 (November 12, 1987) · Model years: 1987

THE RESERVOIR LINE FROM THE SPRING BRAKE CONTROL VALVE WAS CONNECTED TO THE FRONT BRAKE RESERVOIR INSTEAD OF THE REAR RESERVOIR.

Consequence: THIS PLUMBING ERROR AFFECTS THE MANNER IN WHICH THE AIRBRAKES WORK TO STOP THE BUS.

Remedy: INSTALL NEW AIR BRAKE TUBING TO CORRECT PLUMBING ERROR.

Reported: 1988-05-02 (May 2, 1988) · Model years: 1988

A PRESSURE PROTECTION VALVE WAS OMITTED IN FRONT AIR BRAKE PLUMBING THAT IS REQUIRED BY FMVSS 121.

Consequence: IF A LEAK DEVELOPS IN THE AIR BRAKE PLUMBING, AIR INFRONT BRAKES WOULD NOT BE PROTECTED.

Remedy: INSTALL PRESSURE PROTECTION VALVE.

Reported: 1996-01-29 (January 29, 1996) · Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM CAN RESULT IN DAMAGE TO THE BRAKE CHAMBER CLAMP BAND.

Consequence: IF THE DAMAGE TO THE CLAMP BAND RESULTED IN BAND BREAKAGE, THE CHAMBER COULD COME APART RESULTING IN LOSS OF THE SERVICE BRAKES. THE EMERGENCY BRAKES WOULD AUTOMATICALLY APPLY.

Remedy: DEALERS WILL INSPECT THE BRAKE CHAMBER FOR SIGN OF CONTACT. IF CONTACT IS INDICATED, THE BRAKE CAM SHAFT AND CHAMBER SUPPORT BRACKET WILL BE REPLACED, ELIMINATING THE POSSIBLITY OF CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM.

Reported: 1997-03-03 (March 3, 1997) · Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM CAN RESULT IN DAMAGE TO THE BRAKE CHAMBER CLAMP BAND.

Consequence: IF THE DAMAGE TO THE CLAMP BAND RESULTED IN BAND BREAKAGE, THE CHAMBER COULD COME APART RESULTING IN LOSS OF THE SERVICE BRAKES. THE EMERGENCY BRAKES WOULD AUTOMATICALLY APPLY.

Remedy: DEALERS WILL INSPECT THE BRAKE CHAMBER FOR SIGNS OF CONTACT. IF CONTACT IS INDICATED, THE BRAKE CAM SHAFT AND CHAMBER SUPPORT BRACKET WILL BE REPLACED, ELIMINATING THE POSSIBILITY OF CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM.

Reported: 1997-08-22 (August 22, 1997) · Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH IN-LINE SIX ENGINE,"S" TYPE FRAME RAILS AND SIDE MOUNTED BATTERY BOX. THE BATTERY CABLE ROUTING ALLOWS THE POSITIVE CABLE TO CHAFE RESULTING IN A POSSIBLE SHORT CIRCUIT OF THE CABLE.

Consequence: IF AN ELECTRICAL SHORT OCCURS, IT CAN CAUSE LOSS OF POWER TO THE VEHICLE AND A POSSIBLE VEHICLE FIRE.

Remedy: THOMAS BUILT WILL PROVIDE OWNERS WITH REPAIR PARTS AND DETAILED REPAIR PROCEDURES TO SECURE THE CABLE TO PREVENT FURTHER DAMAGE. IF THE OWNER SO DESIRES, THOMAS BUILT WILL PERFORM THE REPAIR FOR THEM.

Reported: 1993-01-01 (January 1, 1993) · Model years: 1990, 1991, 1992, 1993

THE CURRENT PRODUCTION STATIONARY WINDOW ASSEMBLIES ALLOW THE GLASS TO DISENGAGE FROM THE RUBBER AND/OR FRAME.

Consequence: THE WINDOWS DO NOT COMPLY WITH FMVSS 217, "BUS WINDOWRETENTION AND RELEASE."

Remedy: INSTALL TWO RETAINING CLIPS AT EACH NON-COMPLYING WINDOW.

Reported: 1994-08-01 (August 1, 1994) · Model years: 1992, 1993, 1994

A SUDDEN HYDRAULIC PRESSURE LOSS DURING HARD TURNS RESULTS IN A MOMENTARY LOSS OF POWER STEERING ASSIST. THE PRESSURE LOSS OCCURS WHEN THE HYDRAULICALLY DRIVEN ENGINE COOLING FAN TURNS OFF IN THE TURN.

Consequence: THE DRIVER REACTS TO THE LOSS OF POWER STEERING ASSIST BY OVERSTEERING, WHICH COULD RESULT IN A VEHICLE ACCIDENT.

Remedy: THE HYDRAULIC CONTROL VALVES WILL BE REPLACED WITH VALVES OF A NEW DESIGN. UNTIL SUCH TIME AS PARTS ARE AVAILABLE, OWNERS WILL BE INSTRUCTED TO DISCONNECT THE FAN CUTOFF SWITCH SO THAT HYDRAULICALLY DRIVEN FANS WILL RUN FULL TIME, ELIMINATING THE PRESSURE SPIKE.

Reported: 1996-09-05 (September 5, 1996) · Model years: 1992, 1993, 1994, 1995, 1996

AN ITEM WORN BY A CHILD, SUCH AS A LONG DRAWSTRING, SASH, OR BACKPACK/BOOKBAG ACCESSORY, CAN BECOME CAUGHT ON THE FATENERS THAT SECURE THE HANDRAIL SUPPORT TO THE HANDRAIL.

Consequence: IF AN ITEM WORN BY A CHILD WERE TO CATCH ON THIS AREA, AND THE DRIVER WERE TO CLOSE THE DOOR AND PUT THE VEHICLE IN MOTION, THIS CAN RESULT IN SERIOUS INJURY OR DEATH.

Remedy: THE EXISTING 1" BOLTS THAT SECURE THE HANDRAIL SUPPORT WILL BE REPLACED WITH 1/2" BOLTS.

Reported: 1995-01-11 (January 11, 1995) · Model years: 1993, 1994

THE METAL HOUSING OF THE SAFETY BELT RETRACTORS ON AUTOMATIC LOCKING RETRACTOR/EMERGENCY LOCKING RETRACTOR SAFETY BELTS CAN BECOME DEFORMED PREVENTING EXTENSION AND/OR RETRACTION OF THE BELT.

Consequence: PASSENGERS WOULD BE UNABLE TO EXTEND OR RETRACT THEIR SAFETY BELTS AND WOULD BE AT A RISK OF INJURY IN THE EVENT OF AN ACCIDENT.

Remedy: DEALERS WILL INSTALL A HARDENED WASHER WHICH WILL DECREASE THE POSSIBILITY OF DEFORMATION OF THE SAFETY BELT RETRACTOR. DAMAGED RETRACTORS WILL BE REPLACED.

Reported: 1995-08-07 (August 7, 1995) · Model years: 1993, 1994

THE AUTOMATIC TRANSMISSION WILL NOT SHIFT INTO LOW GEAR DUE TO A MISALIGNMENT IN THE PRNDL INDICATOR.

Consequence: PRNDL MISALIGNMENT CAN CAUSE THE DRIVER TO BE UNAWAREOF THE GEAR POSITION INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

Remedy: DEALERS WILL CORRECT THE MISALIGNMENT OF THE AUTOMATIC TRANSMISSION.

Reported: 1995-09-25 (September 25, 1995) · Model years: 1993, 1994, 1995

SOME TEMPERATURE SENSITIVE TRIGGERS WERE NOT X-RAYED. THESE TRIGGERS COULD CONTAIN INTERNAL VOIDS THAT WOULD MAKE THE TRIGGERS SUSCEPTIBLE TO ADVANCED CREEP CAUSING FALSE ACTIVATION AND VENTING OF THE CNG.

Consequence: VENTING OF THE CNG COULD RESULT IN A FIRE.

Remedy: THOMAS BUILT WILL REPLACE THE TYPE III PRESSURE RELIEF VALVE WITH THE NEWER DESIGN "GENERATION 2.5" PRESSURE RELIEF DEVICE.

Reported: 1994-09-07 (September 7, 1994) · Model years: 1994

THE AIR COMPRESSOR THAT DRIVES THE POWER STEERING PUMP CAN FAIL, RESULTING IN LOSS OF POWER STEERING ASSIST.

Consequence: LOSS OF POWER STEERING ASSIST CAN CAUSE LOSS OF STEERING CONTROL RESULTING IN AN ACCIDENT.

Remedy: DEALERS WILL REPLACE THE AIR COMPRESSOR WITH A NEW, HIGH CAPACITY AIR COMPRESSOR.

Reported: 1995-03-03 (March 3, 1995) · Model years: 1994

THE AIR CONDITIONING HOSE COVERS DO NOT MEET THE HEAD IMPACT REQUIREMENTS OF FMVSS NO. 222, "SCHOOL BUS PASSENGER SEATING AND CRASH PROTECTION."

Consequence: CONSEQUENCE OF NON-COMPLIANCE: THIS CONDITION CAN CAUSE PERSONAL INJURY IN A VEHICLE CRASH.

Remedy: DEALERS WILL REROUTE THE COVER FROM THE HEAD IMPACT ZONE AND ALSO REPLACE THE METAL COVER WITH A PLASTIC COVER.

Reported: 1995-05-01 (May 1, 1995) · Model years: 1994, 1995

THE ROOF HATCHES ON THESE BUSES DO NOT MEET THE EXTERIOR HANDLE REQUIREMENTS OF FMVSS NO. 217, "BUS WINDOW RETENTION AND RELEASE."

Consequence: CONSEQUENCE OF NON-COMPLIANCE: IN THE EVENT OF AN EMERGENCY, RESCUE PERSONNEL MAY NOT BE ABLE TO OPEN THE ROOF HATCHES FROM THE OUTSIDE.

Remedy: DEALERS WILL REMOVE THE EXISTING ROOF HATCH LID AND REPLACE IT WITH A LID EQUIPPED WITH AN EXTERIOR HANDLE.

Reported: 1997-02-12 (February 12, 1997) · Model years: 1994, 1995, 1996

THE NUT THAT SECURES THE VEHICLE'S MAIN POWER SUPPLY CAN LOOSEN CAUSING LOSS OF CONTACT.

Consequence: THIS CONDITION CAN RESULT IN A LOSS OF VEHICLE POWER INCREASING THE RISK OF A VEHICLE CRASH.

Remedy: THOMAS BUILT WILL SHIP REPAIR PARTS AND A DETAILED REPAIR PROCEDURE TO THE BUS OWNERS. THE REPAIR WILL CONSIST OF REMOVING THE ORIGINAL NUT, LOCATED AT THE ELECTRICAL PANEL, THAT SECURES THE VEHICLE'S MAIN POWER SUPPLY, AND REPLACING IT WITH A FLAT WASHER AND LOCKING NUT.

Reported: 2004-08-12 (August 12, 2004) · Model years: 1995, 1996

CERTAIN 1995 AND 1996 MY THOMAS BUILT SCHOOL BUSES BUILT BETWEEN JANUARY 1, 1995, AND FEBRUARY 29, 1996, WHICH ARE PREDOMINATELY OPERATED ON UNIMPROVED ROADS MAY HAVE DEVELOPED CRACKS IN THE BUS BODY FRAMING STRUCTURE MEMBERS (RAFTERS) NEAR THE HORIZONTAL WINDOW HEADER WELDS AND AT THE SIDE EMERGENCY EXIT DOORS.

Consequence: IN THE EVENT OF A CRASH, PASSENGERS COULD BE SERIOUSLY INJURED.

Remedy: THOMAS BUILT WILL NOTIFY ITS CUSTOMERS AND PROVIDE A FREE REMEDY. THE RECALL BEGAN AUGUST 5, 2005. OWNERS WHO DO NOT RECEIVE A FREE REMEDY WITHIN A REASONABLE AMOUNT OF TIME SHOULD CONTACT THOMAS BUILT CUSTOMER SUPPORT OFFICE AT 336-889-4871.

Reported: 1997-02-18 (February 18, 1997) · Model years: 1995, 1996

THESE BUSES WITH GROSS VEHICLE WEIGHT RATINGS (GVWR) OF 36,200, DO NOT MEET THE BRAKE SIZE AND POWER REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 121, "AIR BRAKE SYSTEMS," FOR VEHICLES OF THAT GVWR.

Consequence: THESE BUSES DO NOT MEET THE REQUIREMENTS OF FMVSS NO. 121.

Remedy: THOMAS BUILT WILL PROVIDE THE OWNERS WITH REPAIR PARTS AND A DETAILED REPAIR PROCEDURE. THE REPAIR WILL CONSIST OF CHANGING THE ORIGINAL REAR SLACK ADJUSTERS AND FRONT BRAKE CHAMBERS AND INCREASING THE AIR RESERVOIR VOLUME.

Reported: 1997-11-01 (November 1, 1997) · Model years: 1995, 1996, 1997

VEHICLE DESCRIPTION: SCHOOL BUSES. THE FLIP SEATS INSTALLED ON THESE BUSES DO NOT MEET THE REARWARD PUSH REQUIREMENTS OF FMVSS NO. 222, "SCHOOL BUS PASSENGER SEATING AND CRASH PROTECTION."

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY PROTECTED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: OWNERS WILL BE PROVIDED WITH REPAIR PARTS AND A DETAILED REPAIR PROCEDURE. IF AN OWNER SO DESIRES, THOMAS BUILT WILL PERFORM THE REPAIR FOR THEM.

Reported: 1997-01-13 (January 13, 1997) · Model years: 1996

VEHICLE DESCRIPTION: TRANSIT BUSES EQUIPPED WITH ISRINGHAUSEN SEATS IN THE DRIVER POSITION. TWO WELDS LOCATED ON THE BACK REST ADJUSTMENT SIDE OF THE SEAT FRAME DID NOT MEET THE MANUFACTURER'S SPECIFICATIONS.

Consequence: IF THESE WELDS WERE NOT TO SPECIFICATION, BACK REST LOADS COULD CAUSE THE WELDS TO FAIL. THE BACK REST WOULD DISENGAGE FROM THE SEAT FRAME ALLOWING LOSS OF SUPPORT TO THE DRIVER'S TORSO AND POSSIBLY CAUSING LOSS OF CONTROL OF THE VEHICLE.

Remedy: ISRINGHAUSEN IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY CAMPAIGN FOR THIS RECALL. DEALERS WILL INSPECT THESE SEATS AND REPLACE THE SEAT FRAME ASSEMBLY.

Reported: 1997-10-20 (October 20, 1997) · Model years: 1997

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES. IF DEBRIS BECOMES TRAPPED BETWEEN THE PLASTIC CUP, WHICH SEALS THE OPENING WHERE THE STEERING COLUMN COMES THROUGH THE BUS FLOOR AND THE STEERING KNUCKLE, THE STEERING LINKAGE CAN BIND.

Consequence: BINDING OF THE STEERING LINKAGE COULD CAUSE THE DRIVER TO OVER STEER THE VEHICLE, POSSIBLY RESULTING IN LOSS OF CONTROL OF THE VEHICLE OR A CRASH.

Remedy: OWNERS ARE REQUESTED TO REMOVE THE PLASTIC SEAL WHICH WILL LEAVE AN OPENING BETWEEN THE VEHICLE FLOOR AND THE STEERING COLUMN. THOMAS BUILT IS IN THE PROCESS OF DESIGNING A PROPER SEAL FOR THAT AREA, AND THIS SEAL WILL BE SENT TO OWNERS FOR INSTALLATION.

Reported: 2001-03-27 (March 27, 2001) · Model years: 2000, 2001

VEHICLE DESCRIPTION: SCHOOL BUSES. THE ACCELERATOR PEDAL CAN POSSIBLY HANG UP ON THE FLOOR RUBBER.

Consequence: THE DRIVER WOULD BE EXPECTING THE VEHICLE'S SPEED TO DECREASE, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSTALL A STAINLESS STEEL PLATE UNDER THE ACCELERATOR PEDAL. OWNER NOTIFICATION BEGAN JUNE 8, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 1-336-889-4871.

Reported: 2001-11-01 (November 1, 2001) · Model years: 2001

VEHICLE DESCRIPTION: CERTAIN SCHOOL BUSES EQUIPPED WITH SYNTEC SEATS FAIL TO CONFORM TO THE REQUIREMENTS OF FMVSS NO. 222, "SCHOOL BUS PASSENGER SEATING AND CRASH PROTECTION." SOME SEATS (1) FAIL TO MEET THE REQUIRED FOUR INCH CLEARANCE DURING THE TEST PROCEDURE, WHILE STILL MEETING THE POST TEST CONDITION; (2) FAIL TO MEET THE REQUIRED FRONTAL PRE-LOAD WHEN TESTING UNDER CERTAIN CONDITIONS; OR (3) WHILE STILL MEETING THE REQUIRED FORCE/DEFECTION, EXPERIENCE WELD BREAKAGE.

Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY PROTECTED.

Remedy: DEALERS WILL REPLACE THE SEAT FRAME AND THE SEAT BACK CUSHION ON THESE VEHICLES. OWNER NOTIFICATION BEGAN NOVEMBER 13, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 336-889-4871.