1994 Thomas SAF-T-LINER: complaints, problems and recalls

Reported: 1994-08-01 (August 1, 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: 1994-09-07 (September 7, 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: 1995-01-11 (January 11, 1995)

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: 1995-03-03 (March 3, 1995)

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)

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: 1995-08-07 (August 7, 1995)

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)

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: 1996-01-29 (January 29, 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: 1996-07-23 (July 23, 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: 1996-09-05 (September 5, 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: 1997-02-12 (February 12, 1997)

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: 1997-03-03 (March 3, 1997)

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)

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.