2002 Thomas Minotour Recalls

---

NHTSA Campaign Number: 07V142000
Manufacturer: THOMAS BUILT BUSES, INC.
Manufacturer Campaign Number: FL-495
Manufactured Begin Date: January 23rd, 1994
Manufactured End Date: April 15th, 2002
Date of Owner Notification: February 8th, 2008

Defect Summary:
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.

Consequence Summary:
IN THE EVENT OF A VEHICLE CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, POSSIBLY RESULTING IN PERSONAL INJURY.

Corrective Summary:
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 336-889-4871 OR CONTACT FREIGHTLINER AT 800-547-0712.

Recall Notes:
FREIGHTLINER RECALL NO. FL-495.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

---

NHTSA Campaign Number: 05V347000
Manufacturer: THOMAS BUILT BUSES, INC.
Manufacturer Campaign Number: FL-454
Manufactured Begin Date: January 8th, 2002
Manufactured End Date: March 8th, 2005
Date of Owner Notification: September 14th, 2005

Defect Summary:
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.

Consequence Summary:
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.

Corrective Summary:
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.

Recall Notes:
THIS ACTION IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN AND IS NOT BEING CONDUCTED UNDER THE SAFETY ACT.FREIGHTLINER/THOMAS BUILT RECALL NO. FL-454.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236; (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

---

NHTSA Campaign Number: 05V340000
Manufacturer: THOMAS BUILT BUSES, INC.
Manufacturer Campaign Number: FL-454
Manufactured Begin Date: January 8th, 2002
Manufactured End Date: March 8th, 2005
Date of Owner Notification: September 14th, 2005

Defect Summary:
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.

Consequence Summary:
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.

Corrective Summary:
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.

Recall Notes:
FREIGHTLINER/THOMAS BUILT RECALL NO. FL-454.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236; (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

---

NHTSA Campaign Number: 02V318002
Manufacturer: THOMAS BUILT BUSES, INC.
Manufacturer Campaign Number: FL404
Manufactured Begin Date: July 16th, 2002
Manufactured End Date: November 14th, 2002

Defect Summary:
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 ACTUATION PRESSURE.

Consequence Summary:
FREIGHTLINER RECALL NO. FL404. ONCE ENGINE STALL OCCURS, THE ENGINE CANNOT BE RESTARTED, INCREASING THE RISK OF A CRASH.

Corrective Summary:
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 AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CATERPILLAR AT 1-800-447-4986 OR FREIGHTLINER AT 1-800-547-0712.

Recall Notes:
ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

---

NHTSA Campaign Number: 02V220000
Manufacturer: THOMAS BUILT BUSES, INC.
Manufactured Begin Date: March 3rd, 1999
Manufactured End Date: June 26th, 2002
Date of Owner Notification: April 21st, 2003

Defect Summary:
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.

Consequence Summary:
IN THE EVENT OF A CRASH, A SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.

Corrective Summary:
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 WITHIN A REASONABLE TIME SHOULD CONTACT THOMAS BUILT AT 336-889-4871.

Recall Notes:
ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).