FL-839 – Flex Plate Fasteners Improperly Torqued – 2018-2020 Thomas Built Saf-T-Liner HDX School Buses

SEOCONTENT-START

.) . ~ – …..: – . DAIMLER -_-.·;_·::…,
. *->-t’\,,….., • -~ – – – ·: — – • – •• :••J:t”‘”- – -~– – – … _ … – …
—- .- t –…. –
Defect Information Report
(Section 573.6)
FL-839
Date of Submission: November 19, 2019
Manufacturer: Daimler Trucks North America LLC
P.O. BOX 3849
Portland, Oregon 97208
Type of Report: X Safety Defect 0 Non-Compliance
Vehicle Information
Model Yr. Start: 2018
Make: Thomas Built Buses
Model: Saf-T-Liner HDX
Production Dates: Begin: 05/03/2017
Model Yr. End: 2020
End: 04/17/2019
Descriptive Information: Certain Thomas Built Buses Saf-T-Liner HDX School Buses equipped with a
Detroit 008 Engine and an Allison Transmission.
Number potentially involved: 30 Estimated percentage of involve with defect: 100%
Defect/ Noncompliance Description
For this Defect/Noncompliance:
Describe the defect or noncompliance: On certain school buses, the Flex-Plate/Torque Converter
fasteners may not have been properly torqued at the plant. Improperly torqued fasteners at the flex
plate may diminish the clamp load and can become broken or dislodged within the flywheel housing.
If a noncompliance, provide the applicable FMVSS: N/ A
0 Check if this recall only affects products in certain geographic regions.
Describe the safety risk:
If the torque converter bolts are loose or cross threaded, bolts may fall into the flywheel housing. The
loose bolts may lead to illumination of the CEL, damage to the flex plate, or become lodged into the
starter, which could result in a disabled school bus and result in a school bus evacuation procedure in an
uncontrolled traffic situation, increasing the risk of an injury.
-.. …, . – –
DAIMLER —~:~.:-.5~::· .
– — .
. – ·— — – ~
~ ~ —–.- ·-
Chronology of Defect/ Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the
noncompliance decision.: July 2019, DTNA received two reports from the field of broken fasteners in
the flywheel housing on school buses being delivered from the school bus manufacturing plant to the
dealership. The issue was communicated to the school bus manufacturing plant requesting an inspection
to identify potential scope of the issue. July – August 2019, 33 school buses were inspected at the plant.
The inspection indicated all school buses had correctly torqued flex plate/torque converter bolts. August
2019, Thomas Built Buses updated the manufacturing process to ensure the correct torque and loc-tite
was being applied on the flex plate/torque converter bolts as per vehicle specification. August –
November 2019, DTNA began evaluating the process to determine if the bolts were properly installed
and backed out or if the bolts were not properly installed on the reported busses. DTNA evaluated torque
sequence, loc-tite application, and continued to monitor warranty claims and field reports for additional
complaints. The review of field complaints indicated no additional claims outside of the initial two school
buses reported with broken flex-plate/torque converter fasteners. November 12, 2019, DTNA with an
abundance of caution, decided to conduct a voluntary recall campaign on certain school buses that may
have incorrectly torqued Flex-Plate/Torque Converter fasteners.
Identify the Remedy
Describe the defect/noncompliance remedy program, including the manufacture’s plan for
reimbursement.: The Flex Plate/Torque Converter fasteners will be inspected and repaired if necessary
on the identified School buses. Repairs will be performed by Daimler Trucks North America authorized
service facilities. Customer notification will be done by first class mail using Daimler Trucks North
America records to determine the customers affected. Details of the reimbursement plan will be included
in the owner’s notification letter.
Identify the Recall Schedule
Describe the recall schedule for notifications.: Customer notification will be made by first class mail
using Daimler Trucks North America records to determine the customers affected.
Planned Dealer Notification Begin· Date:
Planned Dealer Notification End Date:
Planned Owner Notification Begin Date:
01/17/2020
01/17/2020
01/17/2020
Planned Owner Notification End Date: 01/17/2020
Manufacture’s identification code for this recall (if applicable): FL-839
Andy Jones
Manager
Compliance and Regulatory Affairs

******************************************************

The information contained in this letter supercedes and supplements any related policies and procedures in any previously
released bulletins, the Warranty Manual, and/or previously released letters. Failure to read or distribute this letter will not
exempt addressees from compliance with the information contained herein.
Page 1 of 2
Daimler Trucks North America LLC
REF #:
ICI19-063
Effective:
12/13/2019
Release:
12/09/2019
SUBJECT:
TBB FL839 – Interim Recall Notice
This letter is to inform you that an interim recall notice will be sent to affected customers for upcoming Thomas Built Buses recall FL839 ~ TBB Torque Converter Bolts. The interim notices mail by 12/13/2019. A copy of the notice follows for reference.
This notice is for informational purposes only. There is no action for customers or dealers to take at this time. If customers inquire, please refer them to the interim recall notice and let them know the recall will begin when all preparations are completed.
If you have questions or need further information, contact the Warranty Campaigns Department by submitting an inquiry through the WSC Link on DTNAConnect.
WARRANTY CAMPAIGNS DEPARTMENT
P.O. Box 4090
800-547-0712
Portland, Oregon 97208-4090
ATTENTION: Dealer Principal, Warranty Manager, Service Manager, Parts Manager
Freightliner Dealers – U.S. and Canada
Western Star and Sterling Dealers – U.S. and Canada
FCCC Dealers – U.S. and Canada
Direct Warranty Customers – U.S. and Canada
Export Distributors
If you have questions about this Letter, please submit your inquiry on the Web using the WSC Link on DTNAConnect
Daimler Trucks
North America LLC
December 2019
FL839
Interim Recall Notice
NHTSA #19V-831
IMPORTANT SAFETY RECALL
See enclosed VIN list
Subject: TBB Torque Converter Bolts
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Daimler Trucks North America LLC, on behalf of its wholly owned subsidiary, Thomas Built Buses, Inc., has decided
that a defect which relates to motor vehicle safety exists on specific Model Year 2018-2020 Thomas Built Buses
Saf-T-Liner HDX school buses manufactured May 3, 2017, through April 17, 2019, equipped with a Detroit Diesel DD8
engine and an Allison transmission.
On certain school buses, the flex plate/torque converter fasteners may not have been properly torqued at the plant.
Improperly torqued fasteners may diminish the clamp load and become broken or dislodged. Loose/broken bolts may
cause illumination of the CEL, damage to the flex plate, or become lodged in the starter, which may disable the school
bus. This could result in an evacuation in an uncontrolled traffic situation and increase the risk of injury.
This is the first of two notices you will receive regarding this subject. This letter is to inform you of an upcoming recall to
correct the issue noted above. The repair is being validated and parts are being procured. There is no action for you to
take at this time. You may continue to operate your vehicle.
The second notice will inform you when the final remedy is available. When you receive the second notice, please
contact your authorized Thomas Built Buses dealer to schedule the Recall for your vehicle.
If you have any questions about this recall, please contact the Warranty Campaigns Department at (800) 547-0712,
7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday. If you are not able to have the defect remedied without
charge and within a reasonable time, you may wish to submit a complaint to the Administrator, National Highway Traffic
Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at
(888) 3274236 (TTY: (800) 424-9153); or to https://www.safercar.gov.
We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety.
WARRANTY CAMPAIGNS DEPARTMENT
Enclosure
Daimler Trucks North America LLC
Thomas Built Buses, Inc.
1408 Courtesy Road
High Point, NC 27260
800.547.0712 Phone