1995 Thomas SAF-T-LINER: complaints, problems and recalls

Reported: 2004-08-12 (August 12, 2004)

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: 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: 1995-09-25 (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: 1997-02-18 (February 18, 1997)

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: 1997-03-03 (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.

Reported: 1997-11-01 (November 1, 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.