FL953 – Insufficient Rear Panel Joint Strength – 2020-2023 Thomas Built Saf-T-Liner HDX School Buses

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September 14, 2022 NHTSA CAMPAIGN NUMBER: 22V688000

Insufficient Rear Panel Joint Strength/FMVSS 221

A school bus panel with insufficient joint strength may separate during a crash, increasing the risk of injury.

 

NHTSA Campaign Number: 22V688

Manufacturer Daimler TruckseBay North America, LLC

Components STRUCTURE

Potential Number of Units Affected 1,259

 

Summary

Daimler TruckseBay North America LLC (DTNA) is recalling certain 2020-2023 Thomas Built Saf-T-Liner HDX school buses. The rear exterior side-body panel was manufactured with insufficient joint strength. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 221, “School Bus Body Joint Strength.”

 

Remedy

Dealers will add additional mechanical fasteners to secure the joints, free of charge. Owner notification letters were mailed November 11, 2022. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall FL953.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check for Daimler Trucks North America Recalls

 


November 2022
FL953A
NHTSA #22V-688 (School Bus)
Transport Canada #2022-516 (School Bus)

Subject: Thomas Built Buses Saf-T-Liner HDX Exterior Side Joint

Models Affected: Specific model years 2020-2023 Thomas Built Buses Saf-T-Liner HDX school buses manufactured March 25, 2019, through July, 11, 2022.

 

General Information

Daimler Truck North America LLC (DTNA), on behalf of its wholly owned subsidiary, Thomas Built Buses, has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.

The rear exterior side sheet joints on certain Thomas Built Buses Saf-T-Liner HDX school buses built with 20-gauge side sheet panels and certain fastener configurations.

Additional mechanical fasteners will be added to the joints on affected vehicles. Repairs will be performed by Daimler Truck North America authorized service facilities.

There are approximately 1,289 vehicles involved in this campaign.

 

Additional Repairs

Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns before sale or delivery of a vehicle.

Owners may be liable for any progressive damage that results from failure to complete campaigns within a reasonable time after receiving notification.

 

Work Instructions

Please refer to the attached work instructions.

 

Replacement Parts

Replacement parts are now available and can be obtained by ordering the kit and/or part number(s) listed below from your facing Parts Distribution Center.

If our records show your dealership has ordered any vehicle(s) involved in campaign number FL953, a list of the customers and vehicle identification numbers will be available on DTNA Portal. Please refer to this list when ordering parts for this recall.

Table 1 – Replacement Parts for FL953

Campaign NumberPart DescriptionPart NumberQty.
FL953ATAPPING SCREWTBB 6900324922 ea
BLANK COMPLETION STICKERWAR2601 ea

Table 1

 

Exterior Side Sheet Joint Reinforcement

1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.

NOTE: The main power disconnect switch (MPDS) is located in the battery box compartment.

2. Turn the MPDS to the OFF position.

3. Disconnect the negative battery cables at the batteries.

4. Locate the rear upper exterior side sheet joints. See Fig. 1.

 

IMPORTANT: Seven screws are to be installed on the rear top side sheet joint. Figure 2 shows the locations of the additional screws.

5. Starting with the top joint, place a straight edge vertically along the centerline of the existing screws, and mark the center point between each screw. Make sure that each mark is in the exact center, and vertically in alignment with the existing screws.

6. Use a number-19 drill bit to drill seven holes in the marked locations.

7. Paint the screws (69003249) with the same colour (school bus yellow, typical) as that of the vehicle body.

8. Install the seven screws, shown in Fig. 2. Tighten the screws so they are fully seated.

9. Repeat the steps 5 through 8 to install four screws on the middle rear side sheet joint, as shown in Fig. 3.

 

10. Repeat the steps 5 through 9 to install the screws on the other side of the vehicle.

11. Connect the negative battery cables to the battery.

12. Turn the MPDS to the ON position.

 


Chronology :

On or about August 16 2022, Thomas Built Buses identified a school bus built with rear exterior 20-gauge side sheet joints with lower than expected tensile strength. These side sheet joints were identified during a periodic joint strength verification test. Thomas Built Buses immediately began an investigation to determine the scope and potential impact of this verification finding. On August 26 2022, Thomas Built Buses continued working to identify potentially affected vehicles and conducting additional testing. On September 9 2022, DTNA decided to initiate a voluntary noncompliance recall for certain Thomas Built Buses HDX school buses built with these 20-gauge side sheet joints and with the certain configuration of fasteners that may not meet the joint strength requirements of FMVSS 221 S5.1.

 


4 Affected Products

Vehicle

MAKEMODELYEAR
THOMAS BUILT BUSESSAF-T-LINER HDX2020-2023

 


10 Associated Documents

Defect Information Report

RMISC-22V688-5134.pdf 697.477KB

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Recall Acknowledgement

RCAK-22V688-1386.pdf 645.538KB

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Noncompliance Notice 573 Report

RCLRPT-22V688-2425.PDF 241.93KB

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Manufacturer Notices(to Dealers,etc)

RCMN-22V688-4249.pdf 129.446KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V688-0221.pdf 304.342KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V688-1598.pdf 551.717KB

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Recall Quarterly Report #1, 2022-4

RCLQRT-22V688-2429.PDF 211.157KB

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Recall 573 Report – March 24, 2023

RCLRPT-22V688-2830.PDF 213.614KB

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Recall Quarterly Report #2, 2023-1

RCLQRT-22V688-8934.PDF 211.257KB

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Recall Quarterly Report #3, 2023-2

RCLQRT-22V688-9841.PDF 211.343KB

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