NHTSA vehicle safety data

2002 Freightliner FS-65 Recalls & Complaints

The 2002 Freightliner FS-65 has 3 NHTSA recall campaigns and 5 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Freightliner dealer.

NHTSA recall and complaint data for the 2002 Freightliner FS-65. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2002 Freightliner FS-65 owner complaints

Owners have filed 5 complaints with NHTSA about the 2002 Freightliner FS-65, describing incidents dated January 7, 2005 to October 10, 2014.

Most-cited components

Structure 4 complaints
Fuel/Propulsion System 1 complaint

Newest complaints

ODI #10643908 · Filed October 10, 2014
FRAME IS CRACKED AND NEARLY SEPARATED ABOVE REAR AXLE. *TR
ODI #10476812 · Filed September 24, 2012
TL* THE CONTACT OWNS A 2002 FREIGHTLINER FS65 SCHOOL BUS. THE CONTACT STATED THAT THE CROSS MEMBER FRAME WAS CRACK. THE CONTACT MENTIONED THAT THE FAILURE WAS FOUND AFTER A ROUTINE MAINTENANCE WAS COMPLETED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO OFFERED TO PAY FOR THE PARTS NEEDED FOR…
ODI #10476809 · Filed September 24, 2012
TL* THE CONTACT OWNS A 2002 FREIGHTLINER FS65 SCHOOL BUS. THE CONTACT STATED THAT AFTER COMPLETING A ROUTINE MAINTENANCE ON THE VEHICLE THEY NOTICED THAT THE CROSS MEMBER FRAME WAS CRACK. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE WHO STATED THEY WILL REIMBURSE FOR THE PARTS BUT NOT FOR THE LABOR…

Read all 5 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2002 Freightliner FS-65 in 1 investigation. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Preliminary Evaluation PE02-024: FRONT AIR BRAKE HOSE LEAKAGE
Closed March 25, 2002
- Recall 02V-084

Open and recently closed NHTSA defect investigations

CUMMINS/FUEL LIFT PUMP/STALLING CONDITION

NHTSA #05V205000 · Fuel System, Diesel · NHTSA notice

Reported April 27, 2005 · FREIGHTLINER LLC

Potentially affected: 16,000 vehicles

Freightliner campaign FL-447 · Vehicles built December 1, 1997 – January 31, 2003 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

CERTAIN 1998-2003 MY FREIGHTLINER FS-65 SCHOOL BUS CHASSIS AND MB-45, MB-55, AND XB SHUTTLE BUS CHASSIS, AND THOMAS BUILT BUS: MVP-ER AND MVP-EF SCHOOL BUS AND NON-SCHOOL BUS MODELS EQUIPPED WITH CUMMINS ISB DIESEL ENGINES AND EQUIPPED WITH FEDERAL-MOGAL 12 AND 24 VOLT FUEL LIFT PUMPS. THE FUEL PUMP COULD FAIL TO TRANSFER FUEL APPROPRIATELY CREATING AN ENGINE STALL CONDITION.

Safety consequence

SHOULD THE ENGINE STALL WHILE THE VEHICLE IS IN USE, A POSSIBLE VEHICLE CRASH COULD OCCUR.

Manufacturer remedy

CUMMINS WILL NOTIFY THE CUSTOMERS OF FREIGHTLINER AND THOMAS BUILT AND REPLACE THE FUEL LIFT PUMP FREE OF CHARGE. OWNERS MAY CONTACT CUMMINS AT 1-800-DIESELS.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

FREIGHTLINER/WORN FRONT BRAKE LINE

NHTSA #04V343000 · Service Brakes, Hydraulic — Foundation Components — Hoses, Lines/Piping, and Fittings · NHTSA notice

Reported July 12, 2004 · FREIGHTLINER LLC

Potentially affected: 3,200 vehicles

Freightliner campaign FL-421 · Owners notified August 10, 2004 · Vehicles built September 20, 1996 – June 28, 2002 (per NHTSA)

Defect description

ON CERTAIN SCHOOL BUSES CHASSIS EQUIPPED WITH CATERPILLAR ENGINES AND HYDRAULIC BRAKES. A BRAIDED GROUND STRAP FOR THE STARTER MAY RUB ON A STEEL CHASSIS BRAKE LINE POTENTIALLY CAUSING A FLUID LEAK.

Safety consequence

A BRAKE FLUID LEAK CAN REDUCE BRAKING EFFECTIVENESS AND INCREASE THE STOPPING DISTANCE, WHICH COULD RESULT IN A CRASH.

Manufacturer remedy

DEALERS WILL INSPECT THE BRAKE LINE AND REPLACE IT, IF NECESSARY. THE BRAIDED GROUND STRAP WILL BE REPLACED WITH AN INSULATED CABLE. THE RECALL BEGAN ON AUGUST 10, 2004. OWNERS MAY CONTACT FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-421.ALSO, CUSTOMERS CAN CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

FREIGHTLINER/AIR LINE ROUTING

NHTSA #02V084000 · Service Brakes, Hydraulic — Foundation Components — Hoses, Lines/Piping, and Fittings · NHTSA notice

Reported April 2, 2002 · FREIGHTLINER CORPORATION

Potentially affected: 16,000 vehicles

Freightliner campaign FL-394 · Owners notified April 29, 2002 · Vehicles built February 24, 1999 – March 3, 2002 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

ON CERTAIN SCHOOL BUSES, THE BRAKE HOSES FROM THE CHASSIS TO FRONT BRAKE CHAMBERS COULD DEVELOP LEAKS DUE TO THE HOSE ROUTING THAT COULD OVERSTRESS THE HOSE DURING SHARP TURNS.

Safety consequence

THE VEHICLE COULD HAVE REDUCED BRAKING CAPACITY, INCREASING THE RISK OF A CRASH.

Manufacturer remedy

DEALERS WILL INSPECT FOR IMPROPER ROUTING. IF IMPROPER ROUTING IS FOUND, DEALERS WILL REPLACE AND CORRECT THE HOSE ROUTING. OWNER NOTIFICATION BEGAN APRIL 29, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FREIGHTLINER AT 1-800-547-0712.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

try.vin has no NCAP crash-test rating on file for the 2002 Freightliner FS-65. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

5 owner complaints have been filed with NHTSA for the 2002 Freightliner FS-65.

Structure

ODI #10643908

Incident: October 10, 2014 · Filed: October 10, 2014

FRAME IS CRACKED AND NEARLY SEPARATED ABOVE REAR AXLE. *TR

Structure

ODI #10476812

Incident: September 1, 2012 · Filed: September 24, 2012

TL* THE CONTACT OWNS A 2002 FREIGHTLINER FS65 SCHOOL BUS. THE CONTACT STATED THAT THE CROSS MEMBER FRAME WAS CRACK. THE CONTACT MENTIONED THAT THE FAILURE WAS FOUND AFTER A ROUTINE MAINTENANCE WAS COMPLETED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO OFFERED TO PAY FOR THE PARTS NEEDED FOR THE REPAIRS. THE VEHICLE WAS NOT REPAIR. THE FAILURE MILEAGE WAS 172,982.

Structure

ODI #10476809

Incident: August 1, 2012 · Filed: September 24, 2012

TL* THE CONTACT OWNS A 2002 FREIGHTLINER FS65 SCHOOL BUS. THE CONTACT STATED THAT AFTER COMPLETING A ROUTINE MAINTENANCE ON THE VEHICLE THEY NOTICED THAT THE CROSS MEMBER FRAME WAS CRACK. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE WHO STATED THEY WILL REIMBURSE FOR THE PARTS BUT NOT FOR THE LABOR. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 71,525.

Structure

ODI #10476806

Incident: August 1, 2012 · Filed: September 24, 2012

TL* THE CONTACT OWNS A 2002 FREIGHT-LINER FS65 SCHOOL BUS. THE CONTACT STATED THAT AFTER HAVING ROUTING MAINTENANCE DONE ON THE VEHICLE, HE WAS NOTIFIED THAT THE CROSS MEMBER FRAME HAD DEVELOPED A CRACK. THE MANUFACTURER WAS NOTIFIED WHO STATED THAT THEY WOULD REIMBURSE FOR THE PARTS BUT NOT FOR THE LABOR. THE VEHICLE WAS NOT REPAIR. THE FAILURE MILEAGE WAS 129,210.

Fuel System, Other

ODI #10105924

Incident: January 7, 2005 · Filed: January 7, 2005

ROSEAU SCHOOL DISTRICT OPERATES A FLEET OF 26 BUSES COVERING APPROX. 1000 SQUARE MILES IN AREA. IN 1999 ROSEAU SCHOOLS BEGAN PURCHASING BUSES WITH THE CUMMINS ISB ENGINES (AN ALL ELECTRONIC ENGINE REPLACING THE OLDER "B" ENGINES). THE DISTRICT NOW HAS 8 UNITS WITH THIS PARTICULAR ENGINE. THE DISTRICT HAS BEEN EXPERIENCING TOO MANY PROBLEMS WITH SENSORS, CHECK ENGINE LIGHTS COMING ON AND POWER DERATING WHEN OPERATING THESE ENGINES. A COMMON PROBLEM IS LIFT PUMP FAILURE CAUSING RETOACTIVE FAILURE TO THE INJECTION PUMP (CUMMINS NAME FOR THE INJECTION PUMP IS THE VP44 PUMP). WHEN PUMP FAILURE OCCURS A NUMBER OF THINGS MAY HAPPEN - EITHER THE ENGINE MAY GO INTO THE LIMP MODE WHICH WILL LET THE ENGINE STILL RUN BUT UNDER RESTRICTED POWER, THE ENGINE MAY LOSE POWER AND WITHIN SECONDS RETURN TO FULL POWER OR THE ENGINE MAY JUST STOP AND NOT RESTART. IN THE SCHOOL BUSING INDUSTRY ANY OF THESE TYPE OF FAILURES COULD PRESENT ITSELF AS A SERIOUS SAFETY HAZARD FROM THE BUS SLOWING DOWN AND BEING REARENDED BY ANOTHER VEHICLE, THE LOSS OF POWER WHEN BRAKING OR TURNING CAUSING LOSS OF BRAKES OR POWER STEERING, THE LOSS OF POWER CAUSING STALLING OF THE UNIT IN AN INTERSECTION OR WORSE YET WHEN GOING ACROSS A RAILROAD INTERSECTION. IN OUR SITUATION IN NORTHERN MINNESOTA WE ARE SOMETIMES RUNNING IN SUB-ZERO TEMPERATURES (THIS PAST WEEK AS COLD AS -40 DEGREES BELOW 0). A STRANDED SCHOOL BUS OF KIDS IN THOSE TEMPERATURES COULD CREATE REAL PROBLEMS. THE LIST GOES ON AND ON OF WHAT MAY HAPPEN OR IN SOME CASES HAS ALREADY HAPPENED. OTHERS ARE HAVING SIMILAR PROBLEMS.*AK

Other Freightliner FS-65 model years

Check your 2002 Freightliner FS-65 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Freightliner FS-65 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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