2001 THOMAS MVP ER recalls

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.

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.

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 IS RECALLING 3,773 MY 1996 THROUGH 2002 THOMAS BUILT MVP ER SCHOOL BUSES MANUFACTURED FROM JUNE 8, 1995 THROUGH FEBRUARY 16, 2001, EQUIPPED WITH CATERPILLAR 3116 AND 3126 ENGINES. UN-FUSED POWER CABLES WERE TIE-WRAPPED TO A WIRE BRAID ENGINE FUEL RETURN HOSE. OVER TIME THESE CABLES MAY CHAFE, WEARING THROUGH THE WIRE LOOM AND EVENTUALLY THROUGH THE CABLE INSULATION AND FUEL LINE COVERING IN AN AREA NOT EASILY DETECTABLE DURING NORMAL MAINTENANCE WITHOUT REMOVING THE TIE WRAPS AND OPENING THE WIRE LOOM. UN-FUSED AND UN-SWITCHED POWER CABLES WHICH WEAR THROUGH AND CONTACT THE FUEL LINE WIRE BRAID MAY SHORT CIRCUIT.

IN THE EVENT OF A SHORT CIRCUIT, A VEHICLE FIRE CAN OCCUR.

THOMAS BUILT WILL NOTIFY OWNERS AND INSPECT AND REPLACE THE CABLES AS NECESSARY FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON OR ABOUT NOVEMBER 28, 2008. OWNERS MAY CONTACT THOMAS BUILT AT 1-336-889-4871.

ON CERTAIN SCHOOL BUSES, MISALIGNMENT OF THE FAN DRIVE SYSTEM COMPONENTS CAN CAUSE PREMATURE BELT AND PULLEY BEARING WEAR.

IF THE SCHOOL BUS IS DISABLED BY A COOLING SYSTEM FAILURE AND IS STALLED ON THE SIDE OF THE ROAD, AN INCREASED RISK OF A CRASH RESULTING IN INJURY TO A SCHOOL BUS OCCUPANT COULD OCCUR.

DEALERS WILL REPLACE THE FAN BELT, IDLER PULLEY, AND BELT TENSIONER AND THE PULLEY'S LASER WILL BE ALIGNED. OWNER NOTIFICATION BEGAN JUNE 10, 2002. 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 FREIGHTLINER AT 1-800-547-0712.

CERTAIN 2001-2004 MY THOMAS BUILT MVP-EF, ER TRANSIT, MVP-ER, HD, AND HDX SCHOOL BUSES MANUFACTURED BETWEEN SEPTEMBER 24, 2000, AND MARCH 4, 2004. THE TIE ROD ASSEMBLY CAN FRACTURE AND FAIL, POSSIBLY RESULTING IN COMPLETE SEPARATION.

TIE ROD FAILURE CAN POSSIBLY RESULT IN COMPLETE WHEEL SEPARATION AND A VEHICLE CRASH COULD OCCUR.

THOMAS BUILT WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE TIE ROD ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN SEPTEMBER 6, 2005. OWNERS MAY CONTACT THOMAS BUILT AT (WE DO NOT YET HAVE A TELEPHONE NUMBER).

CERTAIN MY 2000 THROUGH 2003 THOMAS BUILT HDX AND MVP-ER SCHOOL BUSES MANUFACTURED BETWEEN APRIL 23, 2000, AND NOVEMBER 14, 2003. THE SERVICE AIR BRAKE PEDAL, FOR BOTH NON-ADJUSTABLE AND ADJUSTABLE BRAKE PEDALS, MAY CONTACT THE FRONT STRUCTURE ON THE BUS, LIMITING THE MAXIMUM BRAKE FORCE AVAILABLE.

INSUFFICIENT AIR BRAKE PRESSURE MAY CAUSE EXTENDED STOPPING DISTANCES WITHOUT PRIOR WARNING, POSSIBLY RESULTING IN A VEHICLE CRASH.

THOMAS BUILT WILL NOTIFY OWNERS AND REPAIR THE AFFECTED BUSES FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2007. OWNERS CAN CONTACT THOMAS BUILT AT 336-889-4871 OR CONTACT FREIGHTLINER AT 800-547-0712.

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.

A VEHICLE FIRE CAN OCCUR POSSIBLY RESULTING IN A CRASH.

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.

CERTAIN 1998-2003 MY FREIGHTLINER FS-65 SCHOOL BUS CHASSIS AND MB-45, MB-55, AND XB SHUTTLE BUS CHASSIS, AND THOMAS BUILT BUS: MVP-ER AND MVP-EF SCHOOL BUS AND NON-SCHOOL BUS MODELS EQUIPPED WITH CUMMINS ISB DIESEL ENGINES AND EQUIPPED WITH FEDERAL-MOGAL 12 AND 24 VOLT FUEL LIFT PUMPS. THE FUEL PUMP COULD FAIL TO TRANSFER FUEL APPROPRIATELY CREATING AN ENGINE STALL CONDITION.

SHOULD THE ENGINE STALL WHILE THE VEHICLE IS IN USE, A POSSIBLE VEHICLE CRASH COULD OCCUR.

CUMMINS WILL NOTIFY THE CUSTOMERS OF FREIGHTLINER AND THOMAS BUILT AND REPLACE THE FUEL LIFT PUMP FREE OF CHARGE. OWNERS MAY CONTACT CUMMINS AT 1-800-DIESELS.

VEHICLE DESCRIPTION: CERTAIN SCHOOL BUSES FAIL TO COMPLY WITH REQUIREMENTS OF FMVSS NO. 121, "AIR BRAKE SYSTEMS." THESE VEHICLES DO NOT COMPLY DUE TO THE LOW AIR WARNING SYSTEM DETECTING PRESSURE IN ONLY ONE RESERVOIR SYSTEM AND NOT BOTH AS REQUIRED.

THIS DOES NOT MEET THE STANDARD.

DEALERS WILL CORRECT THE LOW AIR PRESSURE SWITCH WIRING. OWNER NOTIFICATION BEGAN JULY 27, 2001. OWNER NOTIFICATION IS EXPECTED TO BEGIN 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 336-881-7219.

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.

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

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.

ON CERTAIN SCHOOL OR TRANSIT BUSES WITH PASSENGER SEAT BELTS WITH RETRACTORS, THE COVER HALVES FOR THE RETRACTABLE PORTION OF THE BELT CAN SEPARATE COMPLETELY AND RELEASE THE SEAT BELT CONNECTOR. IF THIS OCCURS, ONE OF THE LOAD BEARING PINS IN THE CONNECTOR COULD SEPARATE FROM THE CONNECTOR AND RENDER THE SEAT BELT UNUSABLE. IN THE EVENT OF A CRASH, THE SEAT OCCUPANT WOULD NOT BE PROPERLY RESTRAINED RESULTING IN AN INJURY. THE SEAT BELT SUPPLIER, AMSAFE, WILL PROVIDE A SNAP ON "OVER-COVER" TO OWNERS TO PREVENT THE SEAT BELT COVER FROM SEPARATING.

IF THIS OCCURS, ONE OF THE LOAD BEARING PINS IN THE CONNECTOR COULD SEPARATE FROM THE CONNECTOR AND RENDER THE SEAT BELT UNUSABLE. IN THE EVENT OF A CRASH, THE SEAT OCCUPANT WOULD NOT BE PROPERLY RESTRAINED RESULTING IN AN INJURY.

DEALERS WILL PROVIDE A PLASTIC OUTER COVER THAT SNAPS OVER THE EXISTING COVER ON UNITS IN THE FIELD AND WILL REPLACE BROKEN SEAT BELTS FREE OF CHARGE. 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 336-841-5924 OR AMSAFE AT 574-266-8330.

ON CERTAIN SCHOOL AND TRANSIT BUSES, THE WHEEL LUG NUT MAY NOT TIGHTEN COMPLETELY.

THE WHEEL COULD LOOSEN INCREASING THE RISK OF LOSS OF CONTROL OF THE VEHICLE.

DEALERS WILL INSTALL NEW WHEEL STUDS. OWNER NOTIFICATION BEGAN FEBRUARY 28, 2002. 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.

VEHICLE DESCRIPTION: MEDIUM DUTY TRUCKS, FIRE TRUCKS, AND TRANSIT BUSES AND SCHOOL BUSES EQUIPPED WITH ELECTRONIC THROTTLE CONTROL/ACCELERATOR PEDALS SUPPLIED BY WILLIAMS CONTROLS INDUSTRIES. THE WELD ATTACHING THE CLEVIS TO THE PLATE HAS INSUFFICIENT PENETRATION AND COULD ALLOW THE CLEVIS TO SEPARATE FROM THE PLATE.

IF THE CLEVIS SEPARATED FROM THE PLATE WHILE THE VEHICLE WAS IN USE, THE VEHICLE WOULD RETURN TO IDLE, INCREASING THE RISK OF A CRASH.

DEALERS WILL REPLACE THESE PEDALS. OWNER NOTIFICATION BEGAN MARCH 18, 2002. 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 FREIGHTLINER AT 1-800-547-0712.