2004 Thomas Built Buses HDX: recalls and complaints

NHTSA lists 7 recall campaigns for the 2004 Thomas Built Buses HDX. The newest campaign is 08V668000. NHTSA received the report on 17 Dec 2008. The NHTSA record gives the component Fuel System, Other / Delivery / Hoses, Lines/Piping, and Fittings. NHTSA has no complaint on file for this model year. 1 NHTSA investigation names this model year.

The NHTSA recall file shows no do-not-drive advisory and no park-outside advisory on these campaigns.

This page cannot show if a recall applies to one vehicle. The NHTSA VIN lookup shows the unrepaired recalls of one vehicle.

Remedy of the newest campaign, 08V668000, in the NHTSA record

Detroit diesel will notify owners and the vehicles will be repaired with more robust lines and vibration dampers free of charge. Repairs will be performed by authorized detroit diesel distributorships. The recall began on march 9, 2009. Owners may contact detroit diesel 1-313-592-3708 or dtna toll-free at 1-800-547-0712 for more information.

NHTSA VIN lookup

Complaint information entered into NHTSA’s Office of Defects Investigation vehicle owner's complaint database is used with other data sources to identify safety issues that warrant investigation and to determine if a safety-related defect trend exists.
NHTSA publishes these words. Source: NHTSA Datasets and APIs, section Complaints, read on 1 Oct 2026. Complaint file through 30 Sep 2026. Recall file through 30 Sep 2026.

Since the last update

No tracked figure of this page changed in a data update. What the log tracks

All updates to the register

Recall campaigns

7 campaigns, newest first. 332,057 units in total.

08V66800017 Dec 2008Fuel System, Other / Delivery / Hoses, Lines/Piping, and Fittings
08V62200026 Nov 2008Electrical System / Wiring / Fuses and Circuit Breakers
08V08800026 Feb 2008Equipment Adaptive/Mobility
08V08700026 Feb 2008Structure / Body / Door / Hinge and Attachments
07V54400029 Nov 2007Electrical System / Wiring / Fuses and Circuit Breakers
06V1500003 May 2006Equipment Adaptive/Mobility
06V13600025 Apr 2006Electrical System / Wiring / Fuses and Circuit Breakers

08V668000Received 17 Dec 2008. 24,650 units.
Fuel System, Other / Delivery / Hoses, Lines/Piping, and Fittings
Defect, in the NHTSA record
Daimler trucks north america (dtna) is recalling 24,650 school and non-school buses, motor home chassis, and trucks manufactured from march 9, 2004 through august 18, 2006, equipped with epa04 certified mbe900 engines, manufactured by detroit diesel between march 1, 2004, and july 31, 2006. The high pressure fuel lines and transfer tubes may fatigue and fracture.
Consequence, in the NHTSA record
A fractured fuel line may leak diesel fuel possibly resulting in a fire or fuel may be spilled on the road causing a slippery surface, possibly resulting in a vehicle crash.
Remedy, in the NHTSA record
Detroit diesel will notify owners and the vehicles will be repaired with more robust lines and vibration dampers free of charge. Repairs will be performed by authorized detroit diesel distributorships. The recall began on march 9, 2009. Owners may contact detroit diesel 1-313-592-3708 or dtna toll-free at 1-800-547-0712 for more information.
Report filed by DAIMLER TRUCKS NORTH AMERICA. Manufacturer campaign number FL-542. Owner notification date in the NHTSA record: 9 Mar 2009.
08V622000Received 26 Nov 2008. 18,198 units.
Electrical System / Wiring / Fuses and Circuit Breakers
Defect, in the NHTSA record
Daimler trucks is recalling 18,198 my 2003-2009 thomas built er, mvp-er, hdx, and mvp-ef school and transit buses equipped with a dual power switch and manufactured from february 1, 2002 through october 17, 2008. Solid state circuit breakers may trip unnecessarily potentially resulting in a loss of power to the bus chassis and body electrical circuits causing an unexpected loss of engine power and exterior lighting.
Consequence, in the NHTSA record
Unexpected loss of engine power and exterior lighting could result in a vehicle crash.
Remedy, in the NHTSA record
Thomas built bus dealers will replace the solid state dual power switch with a mechanical circuit production (mega fuse). The recall is expected to begin during april 2009. Owners may contact thomas built at 1-336-889-4871.
Report filed by DAIMLER TRUCKS NORTH AMERICA. Manufacturer campaign number FL-539. Owner notification date in the NHTSA record: 6 Jul 2009.
08V088000Received 26 Feb 2008. 760 units.
Equipment Adaptive/Mobility
Defect, in the NHTSA record
Daimler trucks is recalling 760 my 2003-2007 thomas built school buses manufactured between july 6, 2005 and july 19, 2006, equipped with braun wheelchair lifts, models nl, ncl, or nvl. The threshold warning systems of the subject model wheelchair lifts fail to comply with the requirements of federal motor vehicle safety standard no. 403, platform lift systems for motor vehicles.
Consequence, in the NHTSA record
Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured.
Remedy, in the NHTSA record
Daimler trucks will notify owners and provide a free remedy which will be performed by thomas built dealerships. The recall began on august 8, 2008. Owners may contact thomas built at 336-889-4871.
Report filed by DAIMLER TRUCKS NORTH AMERICA. Manufacturer campaign number FL-524. Owner notification date in the NHTSA record: 8 Aug 2008.
08V087000Received 26 Feb 2008. 243,435 units.
Structure / Body / Door / Hinge and Attachments
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
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.
Remedy, in the NHTSA record
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.
Report filed by DAIMLER TRUCKS NORTH AMERICA. Manufacturer campaign number FL-525. Owner notification date in the NHTSA record: 18 Aug 2008.
07V544000Received 29 Nov 2007. 33,303 units.
Electrical System / Wiring / Fuses and Circuit Breakers
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
A vehicle fire can occur possibly resulting in a crash.
Remedy, in the NHTSA record
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.
Report filed by FREIGHTLINER LLC. Manufacturer campaign number FL-516. Owner notification date in the NHTSA record: 28 Mar 2008.
06V150000Received 3 May 2006. 45 units.
Equipment Adaptive/Mobility
Defect, in the NHTSA record
Certain my 2004-2007 thomas built minotour, fs65, mvp-ef, and hdx model school buses, manufactured between june 16 and july 1, 2005, equipped with ricon wheelchair lifts. Cracks in the lift arms may allow the mechanism to twist during stowage, preventing closure of the safety interlock switches.
Consequence, in the NHTSA record
In the event this condition occurs during passenger operations it may not be possible to close the lift door causing the vehicle interlocks to remain engaged preventing movement of the vehicle or the ability to load or unload passengers with disabilities from the vehicle.
Remedy, in the NHTSA record
Ricon is conducting this recall (please see 06e008000) and will replace the two vertical arms even if only one arm is cracked free of charge. The recall is expected to begin on may 30, 2006. Owners may contact ricon customer support dept. At 800-322-2884 or owners may contact thomas bus customer support office at 336-889-4871.
Report filed by FREIGHTLINER LLC. Manufacturer campaign number FL-473. Owner notification date in the NHTSA record: 23 Jun 2006.
06V136000Received 25 Apr 2006. 11,666 units.
Electrical System / Wiring / Fuses and Circuit Breakers
Defect, in the NHTSA record
Certain my 2004 through 2006 thomas built hdx, ef, and fs-65 school buses manufactured between october 4, 2004, and february 14, 2006. The body power distribution module (pdm) was manufactured with copper circuits that are too thin for the electrical loads encountered, possibly causing the board to overheat.
Consequence, in the NHTSA record
If the pdm overheats it may generate smoke and could result in a fire.
Remedy, in the NHTSA record
Thomas built will notify owners and will replace the pdm's thin copper circuits with thicker copper circuits. The recall began on june 30, 2006. Owners may contact thomas built at 1-877-660-4938.
Report filed by FREIGHTLINER LLC. Manufacturer campaign number FL-475. Owner notification date in the NHTSA record: 30 Jun 2006.

The campaign number opens the NHTSA record. Each quotation is the text of the NHTSA recall file.

Recall campaign: One recall in the NHTSA recall file, with one campaign number. A campaign can name many makes, models and model years.

Units: The number of vehicles or products that a recall can include. The manufacturer or the firm reports the number to the agency.

Complaints by component

The NHTSA complaint file has no complaint for this model year.

Investigations

NHTSA investigations that name the 2004 Thomas Built Buses HDX
Number	Type	Subject	Component	Opened	Closed	Campaign
PE06012	Preliminary evaluation	ELECTRICAL PANEL FIRES	Electrical System / Wiring / Fuses and Circuit Breakers	8 Mar 2006	15 Jun 2006	06V136000

Investigation: A study of a possible safety defect by the NHTSA Office of Defects Investigation. An investigation with no closing date in the NHTSA file is open.

Other model years

The number under each year is the number of recall campaigns.

A year without a link has fewer than 2 campaigns and fewer than 25 complaints. It has no page.

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Official channels

NHTSA VIN lookupNHTSA shows the unrepaired recalls of one vehicle from its VIN or its license plate.
NHTSA: report a safety problemThe NHTSA form for a complaint about a vehicle, a tire, a child seat or equipment.
NHTSA page of the 2004 Thomas Built Buses HDXThe recalls, the complaints and the investigations that NHTSA shows for this model year.

Cite this page

Recall Register. 2004 Thomas Built Buses HDX: recalls and complaints. https://recallregister.com/vehicle/thomas-built-buses/hdx/2004/. Source: NHTSA Office of Defects Investigation, recall, complaint and investigation files. Data through 30 Sep 2026.

Sources

Source: NHTSA Office of Defects Investigation
Licence: US government work, public domain
Recall file through: 30 Sep 2026
Complaint file through: 30 Sep 2026
First complaint in the file: 1 Jan 1995
Manufacturer in the recall file: DAIMLER TRUCKS NORTH AMERICA

The NHTSA record is the authority. A complaint count is the number of different complaint numbers for the make, the model and the model year. How the register is made. Report an error.

Questions

How many units are in the recall campaigns for the 2004 Thomas Built Buses HDX?: 332,057 units in 7 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the Thomas Built Buses HDX have for all model years?: NHTSA lists 26 recall campaigns for the Thomas Built Buses HDX, model years 2001 to 2023. 7 of them name the 2004 model year.
Is an NHTSA investigation of the 2004 Thomas Built Buses HDX open?: No. The 1 investigation that names this model year has a closing date in the NHTSA file.