Thomas Saf-T-Liner Recalls & Complaints by Model Year
NHTSA lists 25 safety recalls and 5 owner complaints across 25 model years of the Thomas Saf-T-Liner (1977–2002). The most-complained-about year is 2002.
Pick your Thomas Saf-T-Liner model year
- 1977
- 1978
- 1979
- 1980
- 1981
- 1982
- 1983
- 1984
- 1985
- 1986
- 1987
- 1988
- 1989
- 1990
- 1991
- 1992
- 1993
- 1994
- 1995
- 1996
- 1997
- 1998
- 2000
- 2001
- 2002
| Model year | Recalls | Complaints |
|---|---|---|
| 2002 Thomas Saf-T-Liner | 0 | 2 |
| 2001 Thomas Saf-T-Liner | 2 | 1 |
| 2000 Thomas Saf-T-Liner | 1 | 0 |
| 1998 Thomas Saf-T-Liner | 0 | 1 |
| 1997 Thomas Saf-T-Liner | 3 | 0 |
| 1996 Thomas Saf-T-Liner | 10 | 0 |
| 1995 Thomas Saf-T-Liner | 11 | 1 |
| 1994 Thomas Saf-T-Liner | 13 | 0 |
| 1993 Thomas Saf-T-Liner | 10 | 0 |
| 1992 Thomas Saf-T-Liner | 7 | 0 |
| 1991 Thomas Saf-T-Liner | 5 | 0 |
| 1990 Thomas Saf-T-Liner | 5 | 0 |
| 1989 Thomas Saf-T-Liner | 4 | 0 |
| 1988 Thomas Saf-T-Liner | 5 | 0 |
| 1987 Thomas Saf-T-Liner | 3 | 0 |
| 1986 Thomas Saf-T-Liner | 3 | 0 |
| 1985 Thomas Saf-T-Liner | 3 | 0 |
| 1984 Thomas Saf-T-Liner | 3 | 0 |
| 1983 Thomas Saf-T-Liner | 3 | 0 |
| 1982 Thomas Saf-T-Liner | 3 | 0 |
| 1981 Thomas Saf-T-Liner | 2 | 0 |
| 1980 Thomas Saf-T-Liner | 2 | 0 |
| 1979 Thomas Saf-T-Liner | 1 | 0 |
| 1978 Thomas Saf-T-Liner | 1 | 0 |
| 1977 Thomas Saf-T-Liner | 1 | 0 |
What Thomas Saf-T-Liner owners complain about
Across all model years, owners have filed 5 complaints with NHTSA. The 2002 model year has the most, with 2.
All Thomas Saf-T-Liner recalls (25)
Every NHTSA safety campaign that lists a Thomas Saf-T-Liner, most recent first, with the model years each one covers.
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Body (structure)
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.
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…
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Seats
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…
Remedy: 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…
Model years: 2001
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Accelerator pedal (vehicle speed control)
Vehicle description: school buses. The accelerator pedal can possibly hang up on the floor rubber.
Remedy: Dealers will install a stainless steel plate under the accelerator pedal. Owner notification began june 8, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive…
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Seats
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."
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.
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Steering wheel/handle bar (steering)
Vehicle description: school and transit buses. If debris becomes trapped between the plastic cup, which seals the opening where the steering column comes through the bus floor and the steering knuckle, the steering linkage can bind.
Remedy: Owners are requested to remove the plastic seal which will leave an opening between the vehicle floor and the steering column. Thomas built is in the process of designing a proper seal for that area, and this seal will…
Model years: 1997
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Cables (electrical system)
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.
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.
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997
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Chamber (service brakes)
Contact between the brake chamber and the suspension beam can result in damage to the brake chamber clamp band.
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…
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
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Service brakes, air
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.
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…
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Electrical system: wiring
The nut that secures the vehicle's main power supply can loosen causing loss of contact.
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…
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Seats
Vehicle description: transit buses equipped with isringhausen seats in the driver position. Two welds located on the back rest adjustment side of the seat frame did not meet the manufacturer's specifications.
Remedy: Isringhausen is conducting the owner notification and remedy campaign for this recall. Dealers will inspect these seats and replace the seat frame assembly.
Model years: 1996
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Body (structure)
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.
Remedy: The existing 1" bolts that secure the handrail support will be replaced with 1/2" bolts.
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Body (structure)
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
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Chamber (service brakes)
Contact between the brake chamber and the suspension beam can result in damage to the brake chamber clamp band.
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…
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
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Pressure relief devices (fuel system)
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.
Remedy: Thomas built will replace the type iii pressure relief valve with the newer design "generation 2.5" pressure relief device.
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Gear position indication (prndl) (power train)
The automatic transmission will not shift into low gear due to a misalignment in the prndl indicator.
Remedy: Dealers will correct the misalignment of the automatic transmission.
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Glass, side/rear (visibility)
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.
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Air conditioner (equipment)
The air conditioning hose covers do not meet the head impact requirements of FMVSS no. 222, "school bus passenger seating and crash protection."
Remedy: Dealers will reroute the cover from the head impact zone and also replace the metal cover with a plastic cover.
Model years: 1994
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Retractor (seat belts)
The metal housing of the safety belt retractors on automatic locking retractor/emergency locking retractor safety belts can become deformed preventing extension and/or retraction of the belt.
Remedy: Dealers will install a hardened washer which will decrease the possibility of deformation of the safety belt retractor. Damaged retractors will be replaced.
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Pump (steering)
The air compressor that drives the power steering pump can fail, resulting in loss of power steering assist.
Remedy: Dealers will replace the air compressor with a new, high capacity air compressor.
Model years: 1994
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Hydraulic power assist system (steering)
A sudden hydraulic pressure loss during hard turns results in a momentary loss of power steering assist. The pressure loss occurs when the hydraulically driven engine cooling fan turns off in the turn.
Remedy: The hydraulic control valves will be replaced with valves of a new design. Until such time as parts are available, owners will be instructed to disconnect the fan cutoff switch so that hydraulically driven fans will…
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Glass, side/rear (visibility)
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.
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Foot control/valve (service brakes)
A pressure protection valve was omitted in front air brake plumbing that is required by FMVSS 121.
Remedy: Install pressure protection valve.
Model years: 1988
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Hoses, lines/piping, and fittings (service brakes)
The reservoir line from the spring brake control valve was connected to the front brake reservoir instead of the rear reservoir.
Remedy: Install new air brake tubing to correct plumbing error.
Model years: 1987
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Tank assembly (fuel system)
In a front end collision, dual fuel tanks may slide on the support brackets allowing the fuel crossover pipe end fittings to contact a pipe support and protection guard.
Remedy: Install new fuel line guard, fasteners and, if necessary, a fitting.
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Springs (vehicle speed control)
Two throttle return spring defects are involved in this recall. (1) buses equipped with caterpillar engines may have a throttle return spring that breaks and prevents the throttle from returning to idle position when the driver's foot is removed from the accelerator control; (2) buses equipped with cummins vt-225 engines may have the…
Remedy: A repair kit consisting of new spring, mounting bracket and proper repair instructions will be shipped to each owner at no charge and the owner may make his own repairs, or have a thomas distributor or a reputable…
Other Thomas models
- School Bus21 complaints
- Thomas11 complaints
- Bus7 complaints
- Mvp EF7 complaints
- C23 complaints
- FS-653 complaints
- CL1002 complaints
- Conventional2 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.