2004 Thomas Built Buses Fs-65

THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS PRELIMINARY EVALUATIONAFTERBECOMING AWARE THAT FLEETS WERE HAVING HANDLE FAILURES ON THE REAR EMERGENCY DOOR EXIT.THE FAILURE RESULTED IN THE DOOR HANDLE SEPARATING FROM THEDOOR LATCH MECHANISM.WHEN THE HANDLE FAILS, THE REAR EMERGENCY EXIT DOOR CAN NOT BE OPENED FROM OUTSIDE THE BUS.THE FAILURE RESULTS FROM CORROSION OF THE EXTERIOR DOOR HANDLE AROUND THE SECURING ROLL PIN AND SQUARE DRIVE LATCH MECHANISM, CAUSING THE PROTECTIVE FINISH TO CHIP AND FLAKE.CONTINUED CORROSION WEAKENS THE HANDLE AND EVENTUALLY THE HANDLE MAY BREAK WHILE TRYING TO OPEN THE EXIT DOOR.ODI WAS CONCERNED THAT DURING AN EMERGENCY, A PERSON OUTSIDE OF THE BUS WOULD BREAK THE DOOR HANDLE WHILE TRYING TO OPEN THE EMERGENCY EXIT DOOR,POTENTIALLY DELAYING EVACUATION OF THE BUS.UNDER THE SAFETY RECALL, THE ALUMINUM HANDLES WILL BE REPLACED WITH A MORE ROBUST HANDLE.THE RECALL ACTION RESOLVES THE ISSUES RAISED BY THIS INVESTIGATION. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED THIS INVESTIGATION AFTER BECOMING AWARE OF TWO SCHOOL BUS FIRES THAT STARTED IN THE SIDE MOUNTED ELECTRICAL FUSE PANEL ON A PAIR OF THOMAS BUILT SCHOOL BUSES.THEFLEET OWNER HAD REPORTED THE BUS INTERIORS FILLED WITH SMOKE, CERTAIN ELECTRICAL DEVICES BECAME INOPERATIVE, AND THE BUSES STALLED. THE TWO BUSES INVOLVED IN THE FIRE INCIDENTS HAVE CONSECUTIVE VIN NUMBERS AND THE FIRES WERE SIMILAR, BUT NOT IDENTICAL TO A PREVIOUS RECALL (06V-136) CONDUCTED BY THOMAS BUILT.THESE BUSES WERE NOT INCLUDED IN THE PRIOR RECALL, WHICH INVOLVED A DEFECTIVE POWER DISTRIBUTION MODULE (PDM).AFTER FURTHER TECHNICAL EVALUATION, FREIGHTLINER DECIDED THEY WOULD CONDUCT A SAFETY RECALL TO CORRECT DEFICIENCIES IN THEPREVIOUS RECALL AND ALSO EXPAND THE POPULATION TO CAPTURE ALL AFFECTED BUSES.THE CORRECTIVE ACTION FREIGHTLINER PLANS TO TAKE WILL BE FORWARDED TO ODI WHEN AVAILABLE. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

AS A RESULT OF THE ODI INVESTIGATION, FREIGHTLINER HAS AGREED TO RECALL (NUMBER 07V-289) ALL OF THE VEHICLES MANUFACTURED WITH STEERING COLUMNS POTENTIALLY MISSING WELDS.THE RECALL REMEDY WILL INVOLVE INSPECTING THE RECALLED VEHICLES FOR MISSING WELDS AND IF FOUND REPLACE THE STEERING COLUMN.EARLY WARNING AGGREGATE DATA SUBMITTED TO NHTSA BY FREIGHTLINER SUGGESTED THAT A STEERING PROBLEM (EWR CODE 01) EXISTED FOR THE 2004 AND 2005 CENTURY AND COLUMBIA CLASS VEHICLES.THE COUNT OF FIELD REPORTS SUBMITTED FOR THE FIRST QUARTER OF 2006 WAS HIGHER THAN THE AVERAGE OF THE PREVIOUS 6 QUARTERS FOR THE AGGREGATE STEERING DATA.ODI'S FURTHER REVIEW OF THE EWR DATA FOUNDFIELD REPORTS THAT DESCRIBED STEERING COLUMN FAILURES AS A RESULT OF STEERING COLUMN WELDS CRACKING OR BREAKING.INFORMATION RECEIVED FROM FREIGHTLINER DETAILED FAILURES OF THE STEERING COLUMNS ON THE SUBJECT VEHICLES.THESE FAILURES WERE THE RESULT OF MISSING AND CRACKED WELDS ON THE STEERING COLUMN ASSEMBLY.DURING TESTING OF VEHICLES CONTAINING DEFECTIVE STEERING COLUMNS, ODI DETERMINED THAT WELD FAILURES IN THE STEERING COLUMN CREATE A SITUATION WHERE THE VEHICLE BECOMES DIFFICULT TO STEER OR MAY STARTLE THE DRIVER UPON FAILING, THUS PRESENTING A SAFETY RISK.A COPY OF THE RECALL IS ATTACHED.FREIGHTLINER'S ACTION RESOLVES THE ISSUES RAISED BY THIS INVESTIGATION AND, THEREFORE, THIS INVESTIGATION IS CLOSED.

THIS INVESTIGATION WAS OPENED BASED ON FOUR ALLEGATIONS OF SCHOOL BUS FIRES IN THE POWER DISTRIBUTION MODULE (PDM) AREA OF THE SUBJECT BUSES.DURING THE INVESTIGATION, ODI LEARNED THATBUSES BUILT BETWEEN OCTOBER 4, 2004 AND FEBRUARY 14, 2006 WERE EQUIPPED WITH PDM?S MANUFACTURED WITH COPPER CIRCUITS THAT WERE TOO THIN FOR THE ELECTRICAL LOADS ENCOUNTERED, CREATINGOVERHEATING AND THERMAL EVENTS.ALSO, IT WAS DETERMINED THAT MULTIPLE THERMAL BREAKERS, CLUSTERED TOGETHER ON THE PDM, TOGETHER WITH HEAT GENERATED FROM THE PDM CAN GENERATE ENOUGH HEAT TO MELT THE PDM.ON APRIL 21, 2006, FREIGHTLINER FILED A SAFETY RECALL TO ADDRESS THIS ISSUE.FREIGHTLINER'S REMEDY IS TO REPLACE ALL THE ORIGINAL (THIN COPPER CIRCUIT) PDM?S WITH NEW IMPROVED PDM?S HAVING THICKER COPPER CIRCUITS.ALSO, FREIGHTLINER WILL REPLACE THE THERMAL BREAKERS WITH NON-THERMAL BREAKER OR FUSES. THE RECALL ACTION TAKEN BY FREIGHTLINER RESOLVES THE ISSUES RAISED BY THIS INVESTIGATION.THIS INVESTIGATION IS CLOSED.

TL*THE CONTACT OWNS A 2004 THOMAS BUILT FS-65/ FREIGHTLINER SCHOOL BUS. THE CONTACT STATED THAT THE FUSE PANELS AND CABLES LEADING TO THE FUSE PANELS BURNED IN THE VEHICLE. HE REPLACED THE PANELS ON APPROXIMATELY 30 BUSES. HE RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 07V544000 (ELECTRICAL SYSTEM:FUSES AND CIRCUIT BREAKERS), AND STATED THAT THE RECALL SHOULD HAVE BEEN EXTENDED TO THE FUSE PANELS AS WELL. THE CURRENT MILEAGE WAS 68,213 AND FAILURE MILEAGE WAS APPROXIMATELY 35,000.

NHTSA ID

10226823

Incident

May 13, 2005

Mileage

35,000 mi

THOMAS BUILT BUSES: THERE HAVE BEEN REPORTS OF THE FORWARD DOOR LEAF HEX SHAFT BREAKING. *PE