Thomas Minotour Recalls & Complaints by Model Year

NHTSA lists 21 safety recalls and 0 owner complaints across 29 model years of the Thomas Minotour (1977–2005).

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All Thomas Minotour recalls (21)

Every NHTSA safety campaign that lists a Thomas Minotour, most recent first, with the model years each one covers.

1. Seat belts

   NHTSA 07V142000 Reported March 27, 2007 11,265 vehicles potentially affected FREIGHTLINER LLC

   Certain my 1994 through 2002 thomas built minotour, fs-65, mvp-ef, er, and hdx-ef school buses manufactured between january 23, 1994, and april 15, 2002. The seat belt may chafe on the edge of a metal bracket and wear prematurely.

   Remedy: Thomas built will notify owners and replace any chafed seat belts and replace or modify the retainer strip to prevent any further chafing. The recall began on february 8, 2008. Owners may contact thomas built at…

   Model years: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002

2. School bus stop arm assembly (other)

   NHTSA 05V347000 Reported August 3, 2005 5,954 vehicles potentially affected FREIGHTLINER LLC

   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,…

   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…

   Model years: 2002, 2003, 2004, 2005

3. School bus stop arm assembly (other)

   NHTSA 05V340000 Reported July 25, 2005 13,583 vehicles potentially affected FREIGHTLINER LLC

   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,…

   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…

   Model years: 2002, 2003, 2004, 2005

4. Fuel pump (fuel system)

   NHTSA 02V318002 Reported December 3, 2002 2,616 vehicles potentially affected FREIGHTLINER CORPORATION

   On certain trucks equipped with caterpillar 3126e hydraulically controlled electronically actuated unit injected diesel engines with high efficiency pumps (hep8), the pump components may experience a high pressure seal failure which can result in a short period of rough running and subsequent engine stall due to a loss of injection…

   Remedy: Caterpillar is conducting the owner notification and remedy for this campaign. Dealers will inspect the pump serial numbers and replace the pump if necessary. Owners who take their vehicles to an authorized dealer on…

   Model years: 2002

5. Anchorage (seat belts)

   NHTSA 02V220000 Reported August 6, 2002 29 vehicles potentially affected FREIGHTLINER CORPORATION

   Certain school and transit buses fail to comply with the requirements of FMVSS no. 210, "seat belt assembly anchorages." the seat belt anchorages will only hold 4,400 lbs. In lieu of the required 5000 lb.

   Remedy: Dealers will add a fastener to the track mounted seat. Owner notification began april 21, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy…

   Model years: 1999, 2000, 2001, 2002

6. Buckle assembly (seat belts)

   NHTSA 01V097009 Reported June 26, 2001 129 vehicles potentially affected FREIGHTLINER CORPORATION

   Vehicle description: school and transit buses equipped with safety belt assemblies produced by am-safe. On some seat belts, the buckle and connector may unlatch during a collision.

   Remedy: Am-safe notified thomas built's customers to return their vehicle to an authorized dealer to have the seat belts repaired free of charge. Owner notification began september 21, 2000. Owners who take their vehicles to…

   Model years: 2000

7. Anchorage (seat belts)

   NHTSA 99V266000 Reported September 7, 1999 106 vehicles potentially affected THOMAS BUILT BUSES, INC.

   Vehicle description: school buses built on chevrolet chassis with a corrugated steel floor and and equipped with 45" wide restraining passenger seats. The 45" wide restraining passenger seat fails to comply with the performance requirements of FMVSS no. 210, "seat belt assembly anchorages."

   Remedy: Dealers will install two additional anchorage points connecting the seat to the floor.

   Model years: 1993, 1994, 1995, 1996

8. Mounting (fuel system)

   NHTSA 99V174000 Reported July 2, 1999 274 vehicles potentially affected THOMAS BUILT BUSES, INC.

   Vehicle description: school and transit buses built on general motors chassis. To install the new aluminum minotour body, two fuel tank strap fasteners were loosened. Re-tightening these fasteners can result in loss of clamp load, resulting in the fuel tank falling off the vehicle.

   Remedy: Dealers will replace the fasteners.

   Model years: 1997, 1998

9. Body (structure)

   NHTSA 97V117000 Reported July 25, 1997 8,187 vehicles potentially affected THOMAS BUILT BUSES, INC.

   Vehicle description: school buses equipped with manually operated outward opening entrance doors. An item worn by a child, such as a long drawstring, sash, or backpack/bookbag accessory, can becomecaught in the area between the service door and the door control rod attaching bracket.

   Remedy: These buses were originally included in recall campaign 96v-139. However, the repair did not eliminate the potential snagging point between the service door and the door control rod attaching bracket. Therefore, owners…

   Model years: 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

10. Tank assembly (fuel system)

    NHTSA 96V162000 Reported October 1, 1996 517 vehicles potentially affected GENERAL MOTORS CORP.

    Vehicle description: school buses built on GM p3 cutaway chassis. The school bus, when tested in accordance with FMVSS no. 301, exceeded the allowable fuel spillage as specified by the standard. The fuel tank was punctured as a result of the impact of the moving barrier.

    Remedy: General motors is working in conjunction with carpenter, thomas built and u.s. Bus in providing the owner notification and remedy campaign for this recall. Dealers will install new shielding for the fuel tank, new fill…

    Model years: 1992, 1993, 1994, 1995, 1996

11. Tank assembly (fuel system)

    NHTSA 96V162002 Reported September 12, 1996 400 vehicles potentially affected THOMAS BUILT BUSES, INC.

    Vehicle description: school buses built on GM p3 cutaway chassis. The school bus, when tested in accordance with FMVSS no. 301, exceeded the allowable fuel spillage as specified by the standard. The fuel tank was punctured as a result of the impact of the moving barrier.

    Remedy: General motors is working in conjunction with thomas built in providing the owner notification and remedy campaign for this recall. Dealers will add new shielding for the fuel tank, new fill pipe and vent hoses; and,…

    Model years: 1992, 1993, 1994, 1995, 1996

12. Body (structure)

    NHTSA 96V139000 Reported July 23, 1996 120,371 vehicles potentially affected THOMAS BUILT BUSES, INC.

    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.

    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…

    Model years: 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

13. Glass, side/rear (visibility)

    NHTSA 95V087000 Reported May 1, 1995 350 vehicles potentially affected THOMAS BUILT BUSES, INC.

    The roof hatches on these buses do not meet the exterior handle requirements of FMVSS no. 217, "bus window retention and release."

    Remedy: Dealers will remove the existing roof hatch lid and replace it with a lid equipped with an exterior handle.

    Model years: 1994, 1995

14. Labels (equipment)

    NHTSA 94V171000 Reported September 7, 1994 206 vehicles potentially affected THOMAS BUILT BUSES, INC.

    Retroflective markings on required emergency exits do not meet the location requirements of FMVSS no. 217, "bus window retention and release."

    Remedy: Dealers will install additional reflective tape around each emergency door's outside perimeter.

    Model years: 1994

15. Anchorage (seat belts)

    NHTSA 94V059000 Reported April 4, 1994 109 vehicles potentially affected THOMAS BUILT BUSES, INC.

    Safety belt anchorages do not comply with the strength requirements of FMVSS no. 210, "seat belt assembly anchorages."

    Remedy: Dealers will repair these safety belt anchorages.

    Model years: 1993, 1994

16. Glass, side/rear (visibility)

    NHTSA 93V013000 Reported January 1, 1993 24,570 vehicles potentially affected THOMAS BUILT BUSES, INC.

    The current production stationary window assemblies allow the glass to disengage from the rubber and/or frame.

    Remedy: Install two retaining clips at each non-complying window.

    Model years: 1990, 1991, 1992, 1993

17. Hoses, lines/piping, and fittings (fuel system)

    NHTSA 85V154000 Reported November 21, 1985 1,520 vehicles potentially affected THOMAS BUILT BUSES, INC.

    The body is subject to shift forward during an impact and the fuel filler hose and/or fuel vent line hose may separate from either the fuel filler neck or the gas tank. This does not comply with FMVSS 301. Consequence of defect: a fuel spill could occur and possibly result in a fire.

    Remedy: Install new fuel filler and vent line hoses, which are capable of being stretched beyond the extent to which the body could shift forward during a 30 MPH frontal impact.

    Model years: 1982, 1983, 1984, 1985

18. Leaf spring assembly (suspension)

    NHTSA 82V050000 Reported May 8, 1982 185 vehicles potentially affected THOMAS BUILT BUSES, INC.

    The gross axle weight rating listed on the certification plate for the front springs is incorrect. Some vehicles have front springs rated at 2950 lbs. And passenger capacity at greater than 15 passengers. This combination may result in the front springs being overloaded by 150 lbs. When these vehicles are loaded to maximun capacity.

    Remedy: Dealer will replace the front springs with 3100 lb. Front springs at no cost to owner.

    Model years: 1980, 1981, 1982

19. Selector devices (fuel system)

    NHTSA 81V049000 Reported April 7, 1981 9 vehicles potentially affected THOMAS BUILT BUSES, INC.

    Some vehicles may still have a selector switch for an auxiliary fuel tank, although the tank itself has been removed.

    Remedy: Manufacturer will remove the switch and correct the fuel gauge wiring. A fuel tube will also be replaced.

    Model years: 1980

20. Seats

    NHTSA 80V122000 Reported September 23, 1980 57 vehicles potentially affected THOMAS BUILT BUSES, INC.

    Some of the involved vehicles have been released without the seats being properly fastened to the floor and seat rail of the vehicle. This fails to comply with federal motor vehicle safety standard no. 222, "school bus passenger seating and crash protection".

    Remedy: Vehicles will be inspected and corrected by main plant personnel at no charge to owner.

    Model years: 1980

21. Labels (equipment)

    NHTSA 80V124000 Reported September 23, 1980 57 vehicles potentially affected THOMAS BUILT BUSES, INC.

    The involved vehicles have emergency exit labels of less than the two inch height required by federal motor vehicle safety standard no. 217, "bus window retention and release".

    Remedy: Each vehicle will be inspected and corrected by main plant personnel.

    Model years: 1980

Other Thomas models

• School Bus21 complaints
• Thomas11 complaints
• Bus7 complaints
• Mvp EF7 complaints
• Saf-T-Liner5 complaints
• C23 complaints
• FS-653 complaints
• CL1002 complaints

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.