RoadVitals

2002 Thomas Er Recalls

Safety recall campaigns filed with NHTSA that cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
Recall campaignsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
5
Newest Feb 26, 2008
Carrying an NHTSA advisoryCampaigns where NHTSA told owners not to drive the vehicle, or to park it outside, until the repair is done.
0
Open investigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
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1 investigation on file

Recall campaigns

5 campaigns cover this model year — what the defect is, what it could cause, and what the remedy is

08V087000

STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

Feb 26, 2008
243,435 units potentially affected
The defect: DAIMLER TRUCKS IS RECALLING 243,435 MY 1995-2008 THOMAS BUILT SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 1994, AND MARCH 10, 2008. (ADDITIONAL BUSES HAVE BEEN ADDED TO THIS RECALL CAMPAIGN. PLEASE SEE SUPPLEMENTAL REPORT NO. 4) THE EMERGENCY EXIT DOOR HANDLE BEGINS CORRODING AROUND THE SECURING ROLL PIN AND SQUARE DRIVE MECHANISM CAUSING THE PROTECTIVE FINISH TO CHIP AND FLAKE. CONTINUED CORROSION AND PITTING WEAKENS THE HANDLE. HANDLES WEAKENED BY CORROSION MAY BREAK WHILE TRYING TO OPEN THE DOOR FROM THE EXTERIOR.
The risk: IN THE EVENT OF AN EMERGENCY, A PERSON ON THE OUTSIDE OF THE BUS MAY BREAK THE DOOR HANDLE TRYING TO OPEN THE EMERGENCY EXIT POTENTIALLY DELAYING EVACUATION AND INCREASING THE RISK OF PERSONAL INJURY TO THE VEHICLE'S OCCUPANTS.
The remedy: DAIMLER TRUCKS WILL NOTIFY OWNERS AND WILL REPLACE THE HANDLES WITH A MORE ROBUST HANDLE FREE OF CHARGE. REPAIRS WILL BE PERFORMED BY THOMAS BUILT BUSES DEALERSHIPS. THE RECALL BEGAN ON AUGUST 18, 2008, AND NOTIFICATION FOR THE REVISED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT APRIL 29, 2009. OWNERS MAY CONTACT THOMAS BUILT AT 336-889-4871.
DAIMLER TRUCKS NORTH AMERICAManufacturer number FL-525View on NHTSA.gov
07V544000

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

Nov 29, 2007
33,303 units potentially affected
The defect: CERTAIN 2001 THROUGH 2008 THOMAS BUILT FS-56, ER, MVP ER, HDX, AND MVP EF SCHOOL BUSES MANUFACTURED FROM OCTOBER 23, 2000, THROUGH JANUARY 24, 2006, EQUIPPED WITH TYCO PC BOARD AND TYPE II AUTO RESET CIRCUIT BREAKERS. TYPE II AUTO RESET CIRCUIT BREAKER TEMPERATURES MAY EXCEED THE RATING OF THE TYCO PC BOARD CAUSING THE BOARDS TO MELT POTENTIALLY RESULTING IN A VEHICLE FIRE.
The risk: A VEHICLE FIRE CAN OCCUR POSSIBLY RESULTING IN A CRASH.
The remedy: THOMAS BUILT WILL NOTIFY OWNERS AND REPAIR THE BUSES BY REPLACING THE TYPE II AUTO RESET CIRCUIT BREAKERS WITH MANUAL CIRCUIT BREAKERS, AND THE JUMPER CABLE. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT THOMAS BUILT CUSTOMER SUPPORT OFFICE AT 336-889-4871.
FREIGHTLINER LLCManufacturer number FL-516View on NHTSA.gov
05V347000

OTHER:SCHOOL BUS STOP ARM ASSEMBLY

Aug 3, 2005
5,954 units potentially affected
The defect: CERTAIN 2002-2005 MY THOMAS BUILT MINOTOUR, CONVENTIONAL, MVP-ER, ER, HDX, AND MVP-EF MODEL SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 8, 2002, AND MARCH 8, 2005, EQUIPPED WITH SPECIALTY MFG "5" SERIES STOP ARMS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN STATES OTHER THAN THE FOLLOWING STATES: ALASKA, COLORADO, CONNECTICUT, DELAWARE, IDAHO, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, MONTANA, NEBRASKA, NEVADA, NEW HAMPSHIRE, NEW JERSEY, NEW MEXICO, NEW YORK, NORTH DAKOTA, OHIO, OREGON, PENNSYLVANIA, RHODE ISLAND, SOUTH DAKOTA, TENNESSEE, UTAH, VERMONT, VIRGINIA, WASHINGTON, WEST VIRGINIA, WISCONSIN, WYOMING, AND THE DISTRICT OF COLUMBIA. IN EXTREMELY COLD WEATHER, THE MICROSWITCHES USED INTERNALLY TO POSITION THE STOP ARM SIGN IN THE OPEN AND CLOSED POSITIONS MAY MALFUNCTION, CAUSING THE SIGN TO OPEN OR CLOSE IN AN IMPROPER POSITION, OR TO NOT OPEN AT ALL.
The risk: SHOULD THE STOP ARM NOT PERFORM PROPERLY, A CHILD OR PEDESTRIAN MAY BE ENDANGERED BY PASSING VEHICLES SHOULD THE MOTORIST NOT STOP AT THE CORRECT LOCATION.
The remedy: FOR THOSE BUSES OPERATED IN OR NEAR ANY OF THE STATES LISTED ABOVE, THOMAS BUILT IS ENCOURAGING THE BUS OWNERS TO OBTAIN THE REPLACEMENT SWITCH. FOR THOSE BUSES OPERATED IN THE WARMER STATES, DEALERS WILL REPLACE THE SWITCH UPON OWNER REQUEST. FOR THOSE CUSTOMERS WHO REQUEST THE REMEDY, THOMAS BUILT WILL REPLACE THE ORIGINAL SWITCH WITH A SWITCH PACK THAT IS NOT SENSITIVE TO EXTREME COLD WEATHER AND WILL INSPECT TO ENSURE THE MICROSWITCH HEATER WIRING IS PROPERLY CONNECTED. THE RECALL BEGAN ON SEPTEMBER 14, 2005. OWNERS MAY CONTACT THOMAS BUILT'S CUSTOMER SUPPORT OFFICE AT 336-889-4871.
FREIGHTLINER LLCManufacturer number FL-454View on NHTSA.gov
05V340000

OTHER:SCHOOL BUS STOP ARM ASSEMBLY

Jul 25, 2005
13,583 units potentially affected
The defect: CERTAIN 2002-2005 MY THOMAS BUILT MINOTOUR, CONVENTIONAL, MVP-ER, ER, HDX, AND MVP-EF MODEL SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 8, 2002, AND MARCH 8, 2005, EQUIPPED WITH SPECIALTY MFG "5" SERIES STOP ARMS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: ALASKA, COLORADO, CONNECTICUT, DELAWARE, IDAHO, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, MONTANA, NEBRASKA, NEVADA, NEW HAMPSHIRE, NEW JERSEY, NEW MEXICO, NEW YORK, NORTH DAKOTA, OHIO, OREGON, PENNSYLVANIA, RHODE ISLAND, SOUTH DAKOTA, TENNESSEE, UTAH, VERMONT, VIRGINIA, WASHINGTON, WEST VIRGINIA, WISCONSIN, WYOMING, AND THE DISTRICT OF COLUMBIA. IN EXTREMELY COLD WEATHER, THE MICROSWITCHES USED INTERNALLY TO POSITION THE STOP ARM SIGN IN THE OPEN AND CLOSED POSITIONS MAY MALFUNCTION, CAUSING THE SIGN TO OPEN OR CLOSE IN AN IMPROPER POSITION, OR TO NOT OPEN AT ALL.
The risk: SHOULD THE STOP ARM NOT PERFORM PROPERLY, A CHILD OR PEDESTRIAN MAY BE ENDANGERED BY PASSING VEHICLES SHOULD THE MOTORIST NOT STOP AT THE CORRECT LOCATION.
The remedy: THOMAS BUILT WILL NOTIFY ITS OWNERS AND REPLACE THE ORIGINAL SWITCH WITH A SWITCH PACK THAT IS NOT SENSITIVE TO EXTREME COLD WEATHER AND WILL INSPECT TO ENSURE THE MICROSWITCH HEATER WIRING IS PROPERLY CONNECTED FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2005. OWNERS MAY CONTACT THOMAS BUILT'S CUSTOMER SUPPORT OFFICE AT 336-889-4871.
FREIGHTLINER LLCManufacturer number FL-454View on NHTSA.gov
05V208000

VEHICLE SPEED CONTROL

Apr 27, 2005
153 units potentially affected
The defect: CERTAIN MY 2002-2005 THOMAS BUILT SAF-T-LINER ER SCHOOL BUSES AND ER TRANSIT BUSES MANUFACTURED BETWEEN NOVEMBER 2002 AND FEBRUARY 2005 AND EQUIPPED WITH JOHN DEERE 8.1L COMPRESSED NATURAL GAS ENGINES MODELS HFN01 AND HFN03. THE ENGINE CONTROL UNIT AND THROTTLE CAN UNEXPECTEDLY SURGE. THESE UNITS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 124, ACCELERATOR CONTROL SYSTEMS.
The risk: A SUDDEN ENGINE SURGE COULD POSSIBLY RESULT IN A VEHICLE CRASH.
The remedy: JOHN DEERE WILL NOTIFY THE CUSTOMERS OF FREIGHTLINER/THOMAS BUILT AND WILL UPDATE THE ENGINE CONTROL UNIT SOFTWARE FREE OF CHARGE. OWNERS MAY CONTACT JOHN DEERE AT 1-800-JD-ENGINE.
FREIGHTLINER LLCManufacturer number FL-450View on NHTSA.gov

What a recall is

Safety recall
A safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
Safety investigation
NHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
Manufacturer communication
Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect, and it is not a recall.

PE07029ClosedPreliminary Evaluation

SIDE ELECTRICAL FUSE PANEL FIRES

Opened Jun 20, 2007
Closed Nov 29, 2007

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.

ELECTRICAL SYSTEMLed to recall 07V544000

Elsewhere on this vehicle

Data sources