1996 Thomas SAF-T-Liner: recalls and complaints

NHTSA lists 10 recall campaigns for the 1996 Thomas SAF-T-Liner. The newest campaign is 04V398000. NHTSA received the report on 12 Aug 2004. The NHTSA record gives the component Structure / Body. NHTSA has no complaint on file for 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, 04V398000, in the NHTSA record

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 office at 336-889-4871.

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

10 campaigns, newest first. 138,429 units in total.

04V39800012 Aug 2004Structure / Body
97V1920001 Nov 1997Seats
97V13300022 Aug 1997Electrical System / 12v/24v/48v Battery / Cables
97V0300003 Mar 1997Service Brakes, Air / Drum / Chamber
97V02000018 Feb 1997Service Brakes, Air
97V01800012 Feb 1997Electrical System / Wiring
96V17800813 Jan 1997Seats
96V1640005 Sep 1996Structure / Body
96V13900023 Jul 1996Structure / Body
96V02100029 Jan 1996Service Brakes, Air / Drum / Chamber

04V398000Received 12 Aug 2004. 2,125 units.
Structure / Body
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
In the event of a crash, passengers could be seriously injured.
Remedy, in the NHTSA record
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 office at 336-889-4871.
Report filed by FREIGHTLINER LLC. Manufacturer campaign number FL-429.
97V192000Received 1 Nov 1997. 2,391 units.
Seats
Defect, in the NHTSA record
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."
Consequence, in the NHTSA record
In the event of a vehicle crash, the seat occupant may not be properly protected increasing the risk of personal injury.
Remedy, in the NHTSA record
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.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 8 Mar 1999.
97V133000Received 22 Aug 1997. 8,107 units.
Electrical System / 12v/24v/48v Battery / Cables
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
If an electrical short occurs, it can cause loss of power to the vehicle and a possible vehicle fire.
Remedy, in the NHTSA record
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.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 24 Oct 1997.
97V030000Received 3 Mar 1997. 695 units.
Service Brakes, Air / Drum / Chamber
Defect, in the NHTSA record
Contact between the brake chamber and the suspension beam can result in damage to the brake chamber clamp band.
Consequence, in the NHTSA record
If the damage to the clamp band resulted in band breakage, the chamber could come apart resulting in loss of the service brakes. The emergency brakes would automatically apply.
Remedy, in the NHTSA record
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 and the suspension beam.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 28 Apr 1997.
97V020000Received 18 Feb 1997. 55 units.
Service Brakes, Air
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
These buses do not meet the requirements of FMVSS no. 121.
Remedy, in the NHTSA record
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 volume.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 12 May 1997.
97V018000Received 12 Feb 1997. 1,800 units.
Electrical System / Wiring
Defect, in the NHTSA record
The nut that secures the vehicle's main power supply can loosen causing loss of contact.
Consequence, in the NHTSA record
This condition can result in a loss of vehicle power increasing the risk of a vehicle crash.
Remedy, in the NHTSA record
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 supply, and replacing it with a flat washer and locking nut.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 31 Mar 1997.
96V178008Received 13 Jan 1997. 38 units.
Seats
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
If these welds were not to specification, back rest loads could cause the welds to fail. The back rest would disengage from the seat frame allowing loss of support to the driver's torso and possibly causing loss of control of the vehicle.
Remedy, in the NHTSA record
Isringhausen is conducting the owner notification and remedy campaign for this recall. Dealers will inspect these seats and replace the seat frame assembly.
Report filed by THOMAS BUILT BUSES, INC..
96V164000Received 5 Sep 1996. 2,117 units.
Structure / Body
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
If an item worn by a child were to catch on this area, and the driver were to close the door and put the vehicle in motion, this can result in serious injury or death.
Remedy, in the NHTSA record
The existing 1" bolts that secure the handrail support will be replaced with 1/2" bolts.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 2 Dec 1996.
96V139000Received 23 Jul 1996. 120,371 units.
Structure / Body
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
If an item worn by a child were to catch on this area, and the driver were to close the door and put the vehicle in motion, this can result in serious injury or death.
Remedy, in the NHTSA record
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 become snagged.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 8 Oct 1996.
96V021000Received 29 Jan 1996. 730 units.
Service Brakes, Air / Drum / Chamber
Defect, in the NHTSA record
Contact between the brake chamber and the suspension beam can result in damage to the brake chamber clamp band.
Consequence, in the NHTSA record
If the damage to the clamp band resulted in band breakage, the chamber could come apart resulting in loss of the service brakes. The emergency brakes would automatically apply.
Remedy, in the NHTSA record
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 the suspension beam.
Report filed by THOMAS BUILT BUSES, INC.. Owner notification date in the NHTSA record: 8 Apr 1996.

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

The NHTSA investigation file has no investigation that names this model year.

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 1996 Thomas SAF-T-LinerThe recalls, the complaints and the investigations that NHTSA shows for this model year.

Cite this page

Recall Register. 1996 Thomas SAF-T-Liner: recalls and complaints. https://recallregister.com/vehicle/thomas/saf-t-liner/1996/. 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: FREIGHTLINER LLC

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 1996 Thomas SAF-T-Liner?: 138,429 units in 10 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the Thomas SAF-T-Liner have for all model years?: NHTSA lists 25 recall campaigns for the Thomas SAF-T-Liner, model years 1977 to 2002. 10 of them name the 1996 model year.
Is an NHTSA investigation of the 1996 Thomas SAF-T-Liner open?: The NHTSA investigation file has no investigation that names this model year.