February 26, 2020 NHTSA CAMPAIGN NUMBER: 20V113000
Warning Systems May Deactivate
If the exterior warning lights and stop sign indicator stop working, other drivers may inadvertently proceed driving before the school bus loading/unloading of students is complete, increasing the risk of an injury.
NHTSA Campaign Number: 20V113
Manufacturer Daimler Trucks
North America LLC
Components EXTERIOR LIGHTING, OTHER
Potential Number of Units Affected 24,771
Summary
Daimler Trucks North America LLC (DTNA) is recalling certain 2017-2020 Thomas Built Buses Saf-T-Liner C2 school buses configured with a specific Switch Hub Module (part numbers 204803 and 216434) combined with a 500k Bulk Head Module and a certain 3-position momentary switch warning light package. The Switch Hub Module (SHM) that controls the exterior warning lights and stop sign may fail, resulting in deactivation of the red warning lights, stop sign and system indicator.
Remedy
DTNA will notify owners, and dealers will update the SHM, free of charge. The recall began April 15, 2020. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL-844.
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.safercar.gov.
Check for Daimler Trucks North America Recalls
Recall Campaign
April 2020
FL844A
NHTSA#20V-113
Transport Canada #2020-078
Subject: TBB Saf-T-Liner C2 Warning Lights
Models Affected: Specific Thomas Built Buses Saf-T-Liner C2 school buses manufactured January 2, 2019, through February 13, 2020.
General Information
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Thomas Built Buses (TBB), has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.
There are approximately 3,600 vehicles involved in this campaign.
The warning lights and stop sign on buses with a specific combination of switch hub module, bulkhead module, and warning light switch may experience a communication issue, resulting in deactivation of the red warning lights, stop sign, and system indicator. If this happens, drivers may be incorrectly signaled to proceed before loading/unloading of students is complete, increasing the risk of personal injury.
The switch hub module software will be updated to correct the communication issue. 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 not needed for this recall. The repair is a software update.
Removed Parts
Please follow Warranty Failed Parts Tracking shipping instructions for the disposition of all removed parts.
Labor Allowance
Table 2 – Labor Allowance
| Campaign Number | Procedure | Time Allowed (Hours) | SRT Code | Corrective Action |
| FL844-A | Reprogram switch hub module to release 1.24 | 0.2 | 996-R199A | 12 – Repair Recall/Campaign |
Table 1
Claims for Credit
You will be reimbursed for your parts, labor, and handling by submitting your claim through the Warranty system within 30 days of completing this campaign. Please reference the following information in OWL:
- Claim Type is Recall Campaign.
- In the Campaign field, enter the campaign number (FL844-A)
- In the Primary Failed Part field, enter 25-FL844-000.
- Enter nothing In the Parts section. No parts are needed for this repair, it is a software update.
- In the Labor section, enter the appropriate SRT from the Labor Allowance Table.
- The VMRS Component Code is F99-999-005 and the Cause Code is A1 – Campaign.
- U.S. and Canada – Reimbursement for Prior Repairs. When a customer asks about reimbursement, please do the following:
- Accept the documentation of the previous repair.
- Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement.
- Submit a Recall Pre-Approval request for a decision and authorized amount.
- Submit a “based on” claim for the approved pre-approval.
- Attach the documentation to the pre-approval request.
- When your claim is paid, reimburse the customer the appropriate amount.
IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the campaign has not been previously completed.
If you have any questions or need additional information, contact the Warranty Campaigns Department via Web inquiry at DTNAConnect.com / WSC.
To return excess kit inventory related to this campaign, U.S. dealers must submit a Parts Authorization Return (PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing PDC. All kits must be in resalable condition. PAR requests must include the original purchase invoice number.
A sample letter notifying vehicle owners is included for your reference.
Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code, Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors and retail outlets within five working days.
Copy of Notice to Owners
Subject: TBB Saf-T-Liner C2 Warning Lights
The U.S. notice is used for reference: 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 Thomas Built Buses Saf-T-Liner C2 school buses manufactured January 2, 2019, through February 13, 2020.
The warning lights and stop sign on buses with a specific combination of switch hub module, bulkhead module, and warning light switch may experience a communication issue, resulting in deactivation of the red warning lights, stop sign, and system indicator. If this happens, drivers may be incorrectly signaled to proceed before loading/unloading of students is complete, increasing the risk of personal injury.
The switch hub module software will be updated to correct the communication issue.
To arrange for repairs, you should contact your local Thomas Built Buses dealer immediately. The repair should take approximately half an hour and will be performed at no charge to you. You may also confirm your vehicle’s involvement in this recall at this URL: https://dtna-dlrinfo.prd.freightliner.com:48518/VinLookup/vin-module/get VinLookupPage.
You may be liable for any progressive damage that results from your failure to complete the Recall within a reasonable time after receiving notification.
If you do not own the vehicle that corresponds to the identification number(s) which appears on the Recall Notification, please return the notification to the Warranty Campaigns Department with any information you can furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law requires that you forward this notice to your distributors and retail outlets within five working days. If you have paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement. Please see the reverse side of this notice for details.
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.pm, 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) 327-4236 (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.
THOMAS BUILT BUSES WARRANTY DEPARTMENT
Enclosure
Reimbursement to Customers for Repairs Performed Prior to Recall
If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement.
Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Daimler Trucks North America LLC dealer. The following documentation must be presented to your dealer for consideration for reimbursement.
Please provide original or clear copies of all receipts, invoices, and repair orders that show:
- The name and address of the person who paid for the repair.
- The Vehicle Identification Number (VIN) of the vehicle that was repaired.
- What problem occurred, what repair was done, when the repair was done.
- Who repaired the vehicle.
- The total cost of the repair expense that is being claimed.
- Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt).
Reimbursement will be made by check from your Daimler Trucks North America LLC dealer. Please speak with your Thomas Built Buses authorized dealer concerning this matter.
Work Instructions
Subject: TBB Saf-T-Liner C2 Warning Lights
Models Affected: Specific Thomas Built Buses Saf-T-Liner C2 school buses manufactured January 2, 2019, through February 13, 2020.
Switch Hub Module Reprogramming
DOWNLOAD FILE (Before Beginning the Recall on the First Bus)
- On the computer(s) to be used for this procedure, use the link below to go to the file needed on the Thomas Dealer Portal:
After logging in, click on the indicated file, see Figure 1:
- Save 24.exe to the desktop of the computer. An icon will appear on the desktop. See Figure 2.
REPROGRAM SWITCH HUB MODULE
- Park the vehicle on a level surface, turn the key completely off, put the bus in Park, and set the parking brake. Chock the tires.
- Open the file (click the icon on the desktop).
- Select Configure Driver (must be done each time the software is opened). See Figure 3.
- Click Select in the RP1210B Setup dialog box, then choose the device from the list that matches your tool. See Figure 4.
- The tool/device name will show in the first field. Check the Override Device Defaults box, change the baud rate from 250000 to 500000, then click OK. See Figure 5.
- Connect the diagnostic tool to the 9-pin connector.
- Turn the ignition to the On position, the engine does not need to be running.
- Click Read Software Version to confirm the connection to the bus and the current software level, for example, 1.23 or 1.22 will be displayed in the SHM: field. See Figure 6.
- Click Program 01.24. Programming will start. Progress will be shown in the Programming Status When complete, 100% will be shown and a message confirming success will be displayed. If you get an error message, select Program 01.24 again to restart. See Figure 7.
- Turn the ignition to “Off.”
- Disconnect the diagnostic tool from the 9-pin connector.
- Remove the chocks from the tires.
Memorandum
To: All TBB Dealers
From: Michael Stotler
Date: 4/13/2020
Re: Information regarding recall FL844 SHM reprogramming
Recall FL844 SHM reprogramming release
The recall will be released onto DTNA Connect on 4/8/2020. I want to thank all of the dealers that reacted quickly to address this issue and get many of these done prior to the official release, due to the importance of this recall. Since we first announced this pending recall, allot of work was still taking place behind the scenes, mainly to identify the cause of the issue. When we first reported this problem to the dealer network, we had over 26,000 buses in the population. We did not know the root cause and “erred on the side of caution”. We have since been able to narrow the population down to just over 6,000 buses. The buses in the population that will require the programing were built 1/2/2019 to 2/13/2020.
Important: For units that have already been reprogrammed ahead of the release, using the original lists sent to you, please create a list of those units and provide them to your dealer manager. You will be reimbursed via policy for those units. The campaign will be open to accepting claims for units on the official population list beginning 04/8/2020. Remember that the claim repair date cannot be earlier than 04/8/2020 or the claim will be rejected by the system.
SHM Program
FL844 draft
2/26/2020
Switch Hub Module will need to be programmed with 1.24 software level. To program a SHM you will need the file located on the Thomas Built Dealer Portal under the section Documents/Reporting tools and then Recall Documents and inside the folder labeled downloads.
Once the file is saved to your desktop you will see this icon
- Open the file
- Each time you open the software you will need to set the configure driver
Select Configure driver
You will need to hit select to choose your adaptor tool driver such as Nexiq USB
The tool will show in the first line. Then select override device defaults box and change the rate from 250000 to 500000 and click ok
You are now ready to program a bus
- Connect your diagnostic tool to the 9 pin connector
- Turn ignition to on position, you do not need the engine running to program
- Click read software version to ensure you are connected to the bus and the current level example 1.23 or 1.22 will be displayed to the right of the box
- Click Program 01.24 and the software will initialize and display the status in the programming status area on the screen. If you get an error that programming failed select program button again to restart. Once complete it will show 100% and provide a message the programing was successful
Programing should take less than 1 minute
- Turn the ignition switch off and disconnect your tool from the diagnostic connector. If programing other buses leave the program open and complete process again starting at step 3
SHM
Key Talking Points
Introduction: The purpose of this call is to communicate an important customer service development concerning the operation of the electrical system in certain Thomas school buses. Our communication will be specific and at this time we will not be able to elaborate or take any additional questions. We realize that there will be many questions but it is imperative that we follow specific NHTSA guidelines. Please keep this information confidential at this time. We do commit to further communication and will do so at the appropriate times and with the appropriate methods. Thank you for your understanding. Here are the key points of our message:
- Thomas Built Buses will be issuing a recall on school buses with selected warning light packages.
- This will impact approximately 27K C2 school buses.
- This recall is being issued with an abundance of caution, while the failure may never happen, the failure when exhibited is as follows: On the affected school buses the switch hub module (SHM) controlling the exterior warning lights and stop sign may experience a communication issue resulting in deactivation of the red warning lights and stop sign.
- All buses with affected warning packages will receive software updates, a procedure that will take less than 10 minutes.
- The software update is available at this time and instructions will be forthcoming on how you can access it. Each affected dealership will receive an email with their VINs and instructions for downloading the software.
- Buses can continue to operate until the repair is completed. This is the verbiage on the 573 report.
(4)(m) Precaution(s) to be taken Prior to Corrective Measures Implementation: Watch for unexpected change of working system indicator and/or movement of signage and crossing arm. Pressing the momentary activation switch will turn the warning lights back on and deploy the stop sign.
RECALL LETTER INFO
- Registered owners will receive communications per the standard recall methodology
HOLD INFO
- All units ready for pickup at TBB are off hold.
That’s what I have to communicate today. I understand that it’s not a pleasant message and I understand that it comes pretty quickly on the heels of another significant one. What I will communicate is that we’ll quickly have information to you and it will be our top priority in the coming weeks.
We thank you again for your understanding and ask for your cooperation with our request for confidentiality. We anticipate NHTSA posting the recall data to their website in the immediate future and wanted to make sure you are aware of this prior to hearing from owners. We do understand that there will be many questions and we will address them at the appropriate time. Thank you for your time today.
SEOCONTENT-START
Defect Information Report
(Section 573.6)
FL-844
Date of Submission: April 15, 2020
Manufacturer: Daimler Trucks North America LLC
P.O. BOX 3849
Portland, Oregon 97208
Type of Report: X Safety Defect ⃝ Non-Compliance
Vehicle Information
Model Yr. Start: 2020 Model Yr. End: 2021
Make: Thomas Built Buses
Model: Saf-T-Liner C2
Production Dates: Begin: 01/02/2019 End: 02/13/2020
Descriptive Information:
School Buses configured with a specific Switch Hub Module (P/N: 204803 and 216434) combined with a
500k Bulk Head Module and certain 3-position momentary switch warning light packages
Number potentially involved: 6,010 Estimated percentage of involve with defect: 5%
Defect / Noncompliance Description
For this Defect/Noncompliance:
Describe the defect or noncompliance:
On the affected school buses the switch hub module (SHM) controlling the exterior warning lights and
stop sign may experience a communication issue resulting in deactivation of the red warning lights, stop
sign, and system indicator.
Describe the safety risk:
If the red exterior warning lights stop flashing, and the stop sign retracts, other drivers may be
incorrectly signaled to stop driving before the school bus loading/unloading of students is complete
therefore increasing the risk to injury.
If applicable, identify the manufacture of the defective or noncompliant component.
John Deere Electronic Solutions
Chronology of Defect / Noncompliance Determination
Provide the chronology of events leading up to the defect decision or test data for the
noncompliance decision.:
January 2020, DTNA received a dealer report concerning a specific exterior warning light option package
working intermittently. DTNA began inspecting school buses at the School Bus Plant. The plant inspection
of 25 vehicles revealed four vehicles had exterior warning lights turning off without additional driver
input after operating continuously for an extended period of time. An inspection conducted by the dealer
of 98 school buses revealed 53 school buses reporting a similar issue. February 2020, DTNA received an
additional dealer report of a school bus exhibiting a similar issue manufactured prior to the parameter
update. February 20, 2020 DTNA with an abundance of caution, decided to conduct a voluntary recall
campaign on school buses equipped with the above configuration. February 2020 – April 2020, DTNA
conducted an in-depth analysis of warranty and test data in conjunction with the SHM supplier. Findings
indicated there were no warranty claims, reports from the field or testing that indicated the issue was
present prior to Jan 2019. April 2020, DTNA amends the 573 defect report to modify the start date of the
recall population to January 2, 2019. No incidents have been reported in the field. Only in unique
circumstances could the issue be replicated.
Identify the Remedy
Describe the defect/noncompliance remedy program, including the manufacture’s plan for
reimbursement.:
The software in the SHM will be updated — Repairs will be performed by Daimler Trucks North America
authorized service facilities. 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: 04/25/2020
Planned Dealer Notification End Date: 04/25/2020
Planned Owner Notification Begin Date: 04/25/2020
Planned Owner Notification End Date: 04/25/2020
Manufacture’s identification code for this recall (if applicable): FL-844
DTNA Representative;
Andy Jones
Manager
Compliance and Regulatory Affairs
4 Affected Products
Vehicle
| MAKE | MODEL | YEAR |
| THOMAS BUILT BUSES | SAF-T-LINER C2 | 2017-2020 |
14 Associated Documents
ISSUED Owner Notification Letter(Part 577)
RCONL-20V113-2249.pdf 53.682KB
Recall 573 Report- Amendment 1
RCLRPT-20V113-7383.PDF 213.852KB
Remedy Instructions and TSB
RCRIT-20V113-3257.pdf 269.83KB
Miscellaneous Document
RMISC-20V113-5251.pdf 903.44KB
Miscellaneous Document
RMISC-20V113-6893.pdf 299.201KB
Recall Acknowledgement
RCAK-20V113-3835.pdf 244.966KB
Miscellaneous Document- Key talking points – Warning Light
RMISC-20V113-9319.pdf 140.031KB
Miscellaneous Document- Email to Dealer
Manufacturer Notices(to Dealers,etc)
RCMN-20V113-7765.pdf 111.215KB
Defect Notice 573 Report
RCLRPT-20V113-3132.PDF 212.93KB
Miscellaneous Document- Defect Information Report
RMISC-20V113-2636.pdf 460.777KB
Recall Quarterly Report #3, 2020-4
RCLQRT-20V113-3860.PDF 211.327KB
Recall Quarterly Report #1, 2020-2
RCLQRT-20V113-7236.PDF 211.139KB
Recall Quarterly Report #2, 2020-3
RCLQRT-20V113-7355.PDF 211.242KB
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- Free Lifetime Updates & Technical Support — Includes free software updates plus responsive technical support for setup, compatibility and everyday truck diagnostics
- Built for Heavy-Duty Trucks in Commercial Service: Go beyond basic passenger-car code reading with a heavy duty truck scanner built for real diesel truck service. Helps owner-operators, fleets, repair shops, used-truck businesses, and logistics teams handle everyday truck maintenance, prepare for DPF service, and troubleshoot with more confidence
- Get Back on the Road Faster with DPF Regen & Reset: Help perform DPF forced regeneration and DPF reset on supported Cummins, PACCAR, Caterpillar, Detroit, HD Volvo, Mack, International, and MaxxForce applications. Built-in CAN3 channel access helps complete regen and basic diagnostics without an extra CAN-3 adapter, so you can address soot-related issues sooner and reduce aftertreatment downtime
- Wide Coverage for Daily Service Needs: Works with Diesel OBD and OBD2 systems across Freightliner, Peterbilt, Kenworth, HD Volvo, Mack, International, Western Star, and more. Read vehicle information, clear fault codes, view live data, and perform oil reset on supported Isuzu, Fuso, and Hino applications—helping fleets and shops complete routine checks faster with fewer workflow delays
- Smarter Tools for Faster, More Reliable Repairs: Topology display, wiring diagrams, Pin Detect, and Pre/Post scan reports help technicians visualize system relationships, locate wiring or connector issues, document faults before service, and verify repairs after service. Clear reports help reduce guesswork, avoid rework, and support customer, fleet, and insurance claim documentation
- Free Software Updates, No Annual Fees: Get free software updates for the life of the device, which may help you save hundreds of dollars compared with subscription-based scanners. One-click software updates help keep your scanner current without extra annual fees, giving fleets, repair shops, and owner-operators better long-term value
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