NHTSA vehicle safety data

2004 Thomas Built Buses SAF-T-Liner HDX Recalls & Complaints

The 2004 Thomas Built Buses SAF-T-Liner HDX has 5 NHTSA recall campaigns and 2 owner complaints 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 SAF-T-Liner HDX. Recall data is refreshed daily from NHTSA.

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

2004 Thomas Built Buses SAF-T-Liner HDX owner complaints

Owners have filed 2 complaints with NHTSA about the 2004 Thomas Built Buses SAF-T-Liner HDX, describing incidents dated April 15, 2008.

Most-cited components

Service Brakes 2 complaints
Wheels 2 complaints

Newest complaints

ODI #10224602 · Filed April 15, 2008
BUSES MANUFACTURED IN SUCH A WAY THAT FRONT HUB PILOTED WHEELS CANNOT BE CENTERED ON HUB CREATING EXCESSIVE VIBRATION AT ALL SPEEDS AND CAUSING AN UNSAFE CONDITION. ADDITIONALLY BRAKES ON THE SAME BUSES ARE CONTINUALLY REPORTED AS BEING EXCESSIVELY LOUD AND VIBRATING SEVERELY WHEN APPLIED. BRAKES…
ODI #10224599 · Filed April 15, 2008
BUSES MANUFACTURED IN SUCH A WAY THAT FRONT HUB PILOTED WHEELS CANNOT BE CENTERED ON HUB CREATING EXCESSIVE VIBRATION AT ALL SPEEDS AND CAUSING AN UNSAFE CONDITION. ADDITIONALLY BRAKES ON THE SAME BUSES ARE CONTINUALLY REPORTED AS BEING EXCESSIVELY LOUD AND VIBRATING SEVERELY WHEN APPLIED. BRAKES…

Read all 2 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Thomas Built Buses SAF-T-Liner HDX 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 PE11-029: Thomas Built CNG Tank Abrasion
Closed February 17, 2012

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.

Exterior Emergency Door Handle may Detach

NHTSA #15V432000 · Structure — Body — Door · NHTSA notice

Reported July 7, 2015 · Daimler Trucks North America LLC

Potentially affected: 103,038 vehicles

Repair completion: 40.53% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign FL-685 · Owners notified December 24, 2015

Defect description

Daimler Trucks North America LLC (DTNA) is recalling certain model year 2002-2013 Thomas Built Buses Saf-T-Liner ER, 2001-2005 Saf-T-Liner Conventional, 2002-2013 Saf-T-Liner MVP-EF, 2013 Saf-T-Liner EFX, 2001-2008 Saf-T-Liner FS65, 2005-2013 Saf-T-Liner C2, 2003-2013 Saf-T-Liner HDX, 2002-2003 Saf-T-Liner MVP-ER, 2002 Vista, and 2002-2003 TL-960 school buses manufactured from February 5, 2001, through May 29, 2012. In the affected vehicles, the stem that connects the outside emergency door handle to the emergency door opening mechanism may corrode.

Safety consequence

If the stem corrodes, the door handle could detach from the emergency door opening mechanism, delaying the opening of the door and the evacuation of the bus. In the event of an emergency, this may increase the risk of injury to the bus occupants.

Manufacturer remedy

DTNA will notify owners, and dealers will either replace the stems or protect them against corrosion, free of charge. Daimler issued an interim notification to owners on August 25, 2015. The recall began on December 24, 2015. Owners may contact DTNA customer service at 1-800-745-8000. DTNA's number for this recall is FL-685.

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.

Exterior Emergency Door Handle may Detach

NHTSA #15V425000 · Structure — Body — Door · NHTSA notice

Reported July 6, 2015 · Daimler Trucks North America LLC

Potentially affected: 3,013 vehicles

Repair completion: 14.58% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign FL-685 · Owners notified December 24, 2015

Defect description

Daimler Trucks North America LLC (DTNA) is recalling certain model year 2002-2004 Thomas Built Buses Saf-T-Liner ER, 2001-2005 Saf-T-Liner Conventional, 2002-2013 Saf-T-Liner MVP-EF, 2013 Saf-T-Liner EFX, 2001-2008 Saf-T-Liner FS65, 2005-2013 Saf-T-Liner C2, 2003-2013 Saf-T-Liner HDX, 2002-2003 Saf-T-Liner MVP-ER, 2002 Vista, and 2002-2003 TL-960 non-school buses. In the affected vehicles, the stem that connects the outside emergency door handle to the emergency door opening mechanism may corrode.

Safety consequence

Manufacturer remedy

DTNA will notify owners, and dealers will either replace the stems or protect them against corrosion, free of charge. An interim notice was mailed to owners on August 28, 2015. The recall began on December 24, 2015. Owners may contact DTNA customer service at 1-800-745-8000. DTNA's number for this recall is FL-685.

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.

TRANSMISSION CONTROL MODULE/CORROSION

NHTSA #09V011000 · Power Train — Automatic Transmission — Control Module (TCM/PCM/TECM) · NHTSA notice

Reported January 13, 2009 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 2,426 vehicles

Manufacturer campaign FL-544 · Owners notified October 19, 2009 · Vehicles built April 1, 2002 – August 30, 2005 (per NHTSA)

Defect description

DAIMLER TRUCKS IS RECALLING 2,426 THOMAS BUILT BUSES MY 2003 THROUGH 2006 SAF-T-LINER HDX SCHOOL AND NON SCHOOL BUSES MANUFACTURED BETWEEN APRIL 1, 2002 THROUGH AUGUST 30, 2005. THE AUTOMATIC TRANSMISSION CONTROL MODULE (VIM) LOCATED BETWEEN THE FRAME RAILS NEAR THE FRONT AXLE AND OUTSIDE THE TRANSMISSION CONTROL MODULE COVER MAY BECOME CORRODED DUE TO WATER AND ROAD SPRAY INTRUSION. VIM CORROSION MAY CAUSE THE STARTER MOTOR TO ENGAGE UNEXPECTEDLY OR THE BACKUP LIGHTS TO OPERATE INTERMITTENTLY.

Safety consequence

UNEXPECTED STARTER ENGAGEMENT OR INTERMITTENT BACKUP LIGHT OPERATION MAY LEAD TO A VEHICLE CRASH OR PERSONAL INJURY.

Manufacturer remedy

DAIMLER TRUCKS WILL NOTIFY OWNERS AND REPAIRS WILL BE PERFORMED BY THOMAS BUILT BUSES DEALERSHIPS AND DIRECT WARRANTY CUSTOMERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 19, 2009. OWNERS MAY CONTACT DAIMLER TRUCKS TOLL-FREE AT 1-800-547-0712.

Notes

DAIMLER TRUCKS' RECALL NO. FL-544.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 <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

SR-7 SPRING BRAKE VALVE ASSEMBLY/BENDIX/PARKER

NHTSA #07V302000 · Service Brakes, Air — Supply — Check Valve · NHTSA notice

Reported July 16, 2007 · FREIGHTLINER LLC

Potentially affected: 75,000 vehicles

Manufacturer campaign FL-504 · Owners notified January 11, 2008 · Vehicles built July 1, 2002 – July 3, 2007 (per NHTSA)

Defect description

CERTAIN FREIGHTLINER SCHOOL BUS CHASSIS, HEAVY TRUCKS, AND THOMAS BUILT SCHOOL BUSES MANUFACTURED BETWEEN JULY 2002 AND JULY 3, 2007, EQUIPPED WITH BENDIX SR-7 SPRING BRAKE CONTROL VALVES. THE PARKER SCV BRASS 90 DEGREE SINGLE CHECK VALVES (SCV) WHICH ATTACH TO THE SUPPLY PORT OF A BENDIX SR-7 SPRING BRAKE MODULATING VALVE CAN BREAK APART. PIECES OF THE PARKER SCV CAN BECOME LODGED INSIDE THE SR-7 SPRING BRAKE MODULATING VALVE, POTENTIALLY CAUSING EITHER LEAKAGE OUT OF THE SR-7 VALVE OR PREVENTING AIR FROM PROPERLY EXHAUSTING FROM THE SR-7 VALVE. ALSO, DUE TO A MANUFACTURING DEFECT IN THE INTERNAL RUBBER CHECK VALVE INSIDE THE SR-7 SPRING BRAKE MODULATING VALVES, THE VALVES CAN BECOME DEFORMED AND NOT SEAT PROPERLY.

Safety consequence

THESE CONDITIONS COULD EITHER RESULT IN LEAKAGE AND CAUSE A DELAY IN THE APPLICATION OF THE SPRING BRAKE WITHOUT WARNING OR POSSIBLY LEAD TO UNINTENDED VEHICLE ROLLAWAY OR BRAKE DRAG WHICH COULD RESULT IN A VEHICLE CRASH, PERSONAL INJURY, OR DEATH.

Manufacturer remedy

FREIGHTLINER WILL NOTIFY OWNERS AND REPAIR THE VEHICLES FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 11, 2008 TO FREIGHTLINER, STERLING, AND FREIGHTLINER CUSTOM CHASSIS OWNERS; TO THOMAS BUILT BUS OWNERS ON FEBRUARY 1, 2008. OWNERS CAN CONTACT FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-504.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.

try.vin has no NCAP crash-test rating on file for the 2004 Thomas Built Buses SAF-T-Liner HDX. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

2 owner complaints have been filed with NHTSA for the 2004 Thomas Built Buses SAF-T-Liner HDX.

Service Brakes, Air; Wheels

ODI #10224602

Incident: April 15, 2008 · Filed: April 15, 2008

BUSES MANUFACTURED IN SUCH A WAY THAT FRONT HUB PILOTED WHEELS CANNOT BE CENTERED ON HUB CREATING EXCESSIVE VIBRATION AT ALL SPEEDS AND CAUSING AN UNSAFE CONDITION. ADDITIONALLY BRAKES ON THE SAME BUSES ARE CONTINUALLY REPORTED AS BEING EXCESSIVELY LOUD AND VIBRATING SEVERELY WHEN APPLIED. BRAKES POSSIBLY RELATED TO UNCENTERED WHEELS. PROBLEM REPORTED TO MANUFACTURER/DEALER NUMEROUS TIMES WITH NO RESOLUTION. *TR

Service Brakes, Air; Wheels

ODI #10224599

Incident: April 15, 2008 · Filed: April 15, 2008

Other Thomas Built Buses SAF-T-Liner HDX model years

Check your 2004 Thomas Built Buses SAF-T-Liner HDX VIN

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