try.vin
Log in

NHTSA vehicle safety data

2004 Thomas Built Buses FS-65 Recalls & Complaints

The 2004 Thomas Built Buses FS-65 has 7 NHTSA recall campaigns and 1 owner complaint on file as of November 3, 2026. Recall repairs are usually free at an authorized Thomas Built Buses dealer.

NHTSA recall and complaint data for the 2004 Thomas Built Buses FS-65. Recall data is refreshed daily from NHTSA.

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

2004 Thomas Built Buses FS-65 owner complaints

Owners have filed 1 complaint with NHTSA about the 2004 Thomas Built Buses FS-65, describing incidents dated May 13, 2005.

Most-cited components

  • Electrical System 1 complaint

The complaint on file reports a fire (owner-reported, not verified by NHTSA).

Newest complaints

  • ODI #10226823 · Filed

    TL*THE CONTACT OWNS A 2004 THOMAS BUILT FS-65/ FREIGHTLINER SCHOOL BUS. THE CONTACT STATED THAT THE FUSE PANELS AND CABLES LEADING TO THE FUSE PANELS BURNED IN THE VEHICLE. HE REPLACED THE PANELS ON APPROXIMATELY 30 BUSES. HE RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 07V544000…

Read the full complaint

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Thomas Built Buses FS-65 in 4 investigations. 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.

Open and recently closed NHTSA defect investigations

Fire Extinguisher May Be Clogged or Inoperable

NHTSA #18V083000 · Equipment · NHTSA notice

Reported January 30, 2018 · Daimler Trucks North America LLC

Potentially affected: 606 vehicles

Repair completion: 1.49% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign FL-759 · Owners notified April 11, 2018 · Vehicles built April 15, 2002 – December 11, 2015 (per NHTSA)

Defect description

Daimler Trucks North America LLC (DTNA) is recalling certain 2002-2017 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner HDX, FS65, and Minotour school buses, equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf

Safety consequence

In the event of a fire, if the fire extinguisher does not function properly, it can increase the risk of injury.

Manufacturer remedy

DTNA will notify owners instructing them to contact Kidde for a replacement fire extinguisher, free of charge. The recall is expected to begin March 30, 2018. Owners may contact DTNA customer service at 1-800-547-0712 or Kidde customer service at 1-855-262-3540 or online at www.kidde.com and click on "Product Safety Recall" for more information. DTNA's number for this recall is FL-759.

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.

FMVSS 403/BRAUN WHEELCHAIR LIFTS/THRESHOLD WARNING

NHTSA #08V088000 · Equipment Adaptive/Mobility · NHTSA notice

Reported February 26, 2008 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 760 vehicles

Manufacturer campaign FL-524 · Owners notified August 8, 2008 · Vehicles built July 6, 2005 – July 19, 2006 (per NHTSA)

Defect description

DAIMLER TRUCKS IS RECALLING 760 MY 2003-2007 THOMAS BUILT SCHOOL BUSES MANUFACTURED BETWEEN JULY 6, 2005 AND JULY 19, 2006, EQUIPPED WITH BRAUN WHEELCHAIR LIFTS, MODELS NL, NCL, OR NVL. THE THRESHOLD WARNING SYSTEMS OF THE SUBJECT MODEL WHEELCHAIR LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, PLATFORM LIFT SYSTEMS FOR MOTOR VEHICLES.

Safety consequence

SHOULD THE THRESHOLD WARNING SYSTEM FAIL TO OPERATE, THE LIFT USER CAN FALL FROM THE VEHICLE AND BE SERIOUSLY INJURED.

Manufacturer remedy

DAIMLER TRUCKS WILL NOTIFY OWNERS AND PROVIDE A FREE REMEDY WHICH WILL BE PERFORMED BY THOMAS BUILT DEALERSHIPS. THE RECALL BEGAN ON AUGUST 8, 2008. OWNERS MAY CONTACT THOMAS BUILT AT 336-889-4871.

Notes

DAIMLER TRUCKS RECALL NO. FL-524.CUSTOMERS MAY 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.

EMERGENCY EXIT DOOR HANDLE

NHTSA #08V087000 · Structure — Body — Door — Hinge and Attachments · NHTSA notice

Reported February 26, 2008 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 243,435 vehicles

Manufacturer campaign FL-525 · Owners notified August 18, 2008 · Vehicles built January 1, 1994 – March 10, 2008 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

DAIMLER TRUCKS IS RECALLING 243,435 MY 1995-2008 THOMAS BUILT SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 1994, AND MARCH 10, 2008. (ADDITIONAL BUSES HAVE BEEN ADDED TO THIS RECALL CAMPAIGN. PLEASE SEE SUPPLEMENTAL REPORT NO. 4) THE EMERGENCY EXIT DOOR HANDLE BEGINS CORRODING AROUND THE SECURING ROLL PIN AND SQUARE DRIVE MECHANISM CAUSING THE PROTECTIVE FINISH TO CHIP AND FLAKE. CONTINUED CORROSION AND PITTING WEAKENS THE HANDLE. HANDLES WEAKENED BY CORROSION MAY BREAK WHILE TRYING TO OPEN THE DOOR FROM THE EXTERIOR.

Safety consequence

IN THE EVENT OF AN EMERGENCY, A PERSON ON THE OUTSIDE OF THE BUS MAY BREAK THE DOOR HANDLE TRYING TO OPEN THE EMERGENCY EXIT POTENTIALLY DELAYING EVACUATION AND INCREASING THE RISK OF PERSONAL INJURY TO THE VEHICLE'S OCCUPANTS.

Manufacturer remedy

DAIMLER TRUCKS WILL NOTIFY OWNERS AND WILL REPLACE THE HANDLES WITH A MORE ROBUST HANDLE FREE OF CHARGE. REPAIRS WILL BE PERFORMED BY THOMAS BUILT BUSES DEALERSHIPS. THE RECALL BEGAN ON AUGUST 18, 2008, AND NOTIFICATION FOR THE REVISED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT APRIL 29, 2009. OWNERS MAY CONTACT THOMAS BUILT AT 336-889-4871.

Notes

DAIMLER TRUCKS RECALL NO. FL-525.CUSTOMERS MAY 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.

AUTO RESET CIRCUIT BREAKERS

NHTSA #07V544000 · Electrical System — Wiring — Fuses and Circuit Breakers · NHTSA notice

Reported November 29, 2007 · FREIGHTLINER LLC

Potentially affected: 33,303 vehicles

Manufacturer campaign FL-516 · Owners notified March 28, 2008 · Vehicles built October 23, 2000 – January 24, 2006 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

CERTAIN 2001 THROUGH 2008 THOMAS BUILT FS-56, ER, MVP ER, HDX, AND MVP EF SCHOOL BUSES MANUFACTURED FROM OCTOBER 23, 2000, THROUGH JANUARY 24, 2006, EQUIPPED WITH TYCO PC BOARD AND TYPE II AUTO RESET CIRCUIT BREAKERS. TYPE II AUTO RESET CIRCUIT BREAKER TEMPERATURES MAY EXCEED THE RATING OF THE TYCO PC BOARD CAUSING THE BOARDS TO MELT POTENTIALLY RESULTING IN A VEHICLE FIRE.

Safety consequence

A VEHICLE FIRE CAN OCCUR POSSIBLY RESULTING IN A CRASH.

Manufacturer remedy

THOMAS BUILT WILL NOTIFY OWNERS AND REPAIR THE BUSES BY REPLACING THE TYPE II AUTO RESET CIRCUIT BREAKERS WITH MANUAL CIRCUIT BREAKERS, AND THE JUMPER CABLE. THE RECALL BEGAN ON MARCH 28, 2008. OWNERS MAY CONTACT THOMAS BUILT CUSTOMER SUPPORT OFFICE AT 336-889-4871.

Notes

FREIGHTLINER RECALL NO. FL-516.CUSTOMERS MAY 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.

DOUGLAS AUTOTEC STEERING COLUMN MISSING WELDS

NHTSA #07V289000 · Steering — Column · NHTSA notice

Reported July 3, 2007 · FREIGHTLINER LLC

Potentially affected: 25,643 vehicles

Manufacturer campaign FL-503 · Owners notified August 30, 2007 · Vehicles built October 23, 2004 – March 21, 2006 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

CERTAIN FREIGHTLINER SCHOOL BUSES AND TRUCKS MANUFACTURED FROM OCTOBER 23, 2004, TO MARCH 21, 2006. DURING THE STEERING COLUMN MANUFACTURING PROCESS TWO WELDS MAY HAVE BEEN MISSING.

Safety consequence

COLUMNS WITH TWO WELDS MISSING MAY FATIGUE AND FRACTURE AND ALLOW THE STEERING WHEEL TO PROGRESSIVELY BE MOVED OUT OF ITS NORMAL POSITION WHICH MAY CAUSE THE STEERING TO RESPOND DIFFERENTLY THAN EXPECTED. IF THIS CONDITION IS IGNORED, A CRASH MAY OCCUR.

Manufacturer remedy

FREIGHTLINER WILL NOTIFY OWNERS AND INSPECT AND REPAIR THE AFFECTED VEHICLE FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 30, 2007. OWNERS CAN CONTACT FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-503.CUSTOMERS MAY 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.

WHEELCHAIR LIFTS/RICON

NHTSA #06V150000 · Equipment Adaptive/Mobility · NHTSA notice

Reported May 3, 2006 · FREIGHTLINER LLC

Potentially affected: 45 vehicles

Manufacturer campaign FL-473 · Owners notified June 23, 2006 · Vehicles built June 16, 2005 – July 1, 2005 (per NHTSA)

Defect description

CERTAIN MY 2004-2007 THOMAS BUILT MINOTOUR, FS65, MVP-EF, AND HDX MODEL SCHOOL BUSES, MANUFACTURED BETWEEN JUNE 16 AND JULY 1, 2005, EQUIPPED WITH RICON WHEELCHAIR LIFTS. CRACKS IN THE LIFT ARMS MAY ALLOW THE MECHANISM TO TWIST DURING STOWAGE, PREVENTING CLOSURE OF THE SAFETY INTERLOCK SWITCHES.

Safety consequence

IN THE EVENT THIS CONDITION OCCURS DURING PASSENGER OPERATIONS IT MAY NOT BE POSSIBLE TO CLOSE THE LIFT DOOR CAUSING THE VEHICLE INTERLOCKS TO REMAIN ENGAGED PREVENTING MOVEMENT OF THE VEHICLE OR THE ABILITY TO LOAD OR UNLOAD PASSENGERS WITH DISABILITIES FROM THE VEHICLE.

Manufacturer remedy

RICON IS CONDUCTING THIS RECALL (PLEASE SEE 06E008000) AND WILL REPLACE THE TWO VERTICAL ARMS EVEN IF ONLY ONE ARM IS CRACKED FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN ON MAY 30, 2006. OWNERS MAY CONTACT RICON CUSTOMER SUPPORT DEPT. AT 800-322-2884 OR OWNERS MAY CONTACT THOMAS BUS CUSTOMER SUPPORT OFFICE AT 336-889-4871.

Notes

FREIGHTLINER RECALL NO. FL-473.CUSTOMERS MAY 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.

ELECTRICAL FIRE

NHTSA #06V136000 · Electrical System — Wiring — Fuses and Circuit Breakers · NHTSA notice

Reported April 25, 2006 · FREIGHTLINER LLC

Potentially affected: 11,666 vehicles

Manufacturer campaign FL-475 · Owners notified June 30, 2006 · Vehicles built October 4, 2004 – February 14, 2006 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

CERTAIN MY 2004 THROUGH 2006 THOMAS BUILT HDX, EF, AND FS-65 SCHOOL BUSES MANUFACTURED BETWEEN OCTOBER 4, 2004, AND FEBRUARY 14, 2006. THE BODY POWER DISTRIBUTION MODULE (PDM) WAS MANUFACTURED WITH COPPER CIRCUITS THAT ARE TOO THIN FOR THE ELECTRICAL LOADS ENCOUNTERED, POSSIBLY CAUSING THE BOARD TO OVERHEAT.

Safety consequence

IF THE PDM OVERHEATS IT MAY GENERATE SMOKE AND COULD RESULT IN A FIRE.

Manufacturer remedy

THOMAS BUILT WILL NOTIFY OWNERS AND WILL REPLACE THE PDM'S THIN COPPER CIRCUITS WITH THICKER COPPER CIRCUITS. THE RECALL BEGAN ON JUNE 30, 2006. OWNERS MAY CONTACT THOMAS BUILT AT 1-877-660-4938.

Notes

FREIGHTLINER RECALL NO. FL-475.CUSTOMERS MAY 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.

Other Thomas Built Buses FS-65 model years

Check your 2004 Thomas Built Buses FS-65 VIN

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

Check a Thomas Built Buses VIN