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NHTSA vehicle safety data

2003 Thomas ER Recalls & Complaints

The 2003 Thomas ER has 6 NHTSA recall campaigns and 1 owner complaint on file as of November 3, 2026. Recall repairs are usually free at an authorized Thomas dealer.

NHTSA recall and complaint data for the 2003 Thomas ER. Recall data is refreshed daily from NHTSA.

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

2003 Thomas ER owner complaints

Owners have filed 1 complaint with NHTSA about the 2003 Thomas ER, describing incidents dated September 14, 2005.

Most-cited components

  • Unknown or Other 1 complaint

Newest complaints

  • ODI #10178816 · Filed

    TL*- THE CONTACT STATED THAT HE DRIVES A 2003 THOMAS BUILT BUS FOR WALLENPAUPACK SCHOOLS IN PA. THE CONTACT STATED THAT HE RECEIVED A RECALL LETTER 09/14/05 FOR THE STOP ASSEMBLY WITH CAMPAIGN# 05V347000. THE COMPANY HAS NOT RESOLVED THE RECALL REPLACEMENT, AND HE RECEIVED HIS 2ND NOTICE FROM THE…

Read the full complaint

NHTSA defect investigations

NHTSA's investigations file lists the 2003 Thomas ER 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.

Open and recently closed NHTSA defect investigations

DUAL POWER SWITCH

NHTSA #08V622000 · Electrical System — Wiring — Fuses and Circuit Breakers · NHTSA notice

Reported November 26, 2008 · DAIMLER TRUCKS NORTH AMERICA

Potentially affected: 18,198 vehicles

Manufacturer campaign FL-539 · Owners notified July 6, 2009 · Vehicles built February 1, 2002 – October 17, 2008 (per NHTSA)

Defect description

DAIMLER TRUCKS IS RECALLING 18,198 MY 2003-2009 THOMAS BUILT ER, MVP-ER, HDX, AND MVP-EF SCHOOL AND TRANSIT BUSES EQUIPPED WITH A DUAL POWER SWITCH AND MANUFACTURED FROM FEBRUARY 1, 2002 THROUGH OCTOBER 17, 2008. SOLID STATE CIRCUIT BREAKERS MAY TRIP UNNECESSARILY POTENTIALLY RESULTING IN A LOSS OF POWER TO THE BUS CHASSIS AND BODY ELECTRICAL CIRCUITS CAUSING AN UNEXPECTED LOSS OF ENGINE POWER AND EXTERIOR LIGHTING.

Safety consequence

UNEXPECTED LOSS OF ENGINE POWER AND EXTERIOR LIGHTING COULD RESULT IN A VEHICLE CRASH.

Manufacturer remedy

THOMAS BUILT BUS DEALERS WILL REPLACE THE SOLID STATE DUAL POWER SWITCH WITH A MECHANICAL CIRCUIT PRODUCTION (MEGA FUSE). THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2009. OWNERS MAY CONTACT THOMAS BUILT AT 1-336-889-4871.

Notes

DAIMLER TRUCK RECALL NO. FL-539.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.

STOP ARM MALFUNCTIONS

NHTSA #05V347000 · Other — School Bus Stop Arm Assembly · NHTSA notice

Reported August 3, 2005 · FREIGHTLINER LLC

Potentially affected: 5,954 vehicles

Manufacturer campaign FL-454 · Owners notified September 14, 2005 · Vehicles built January 8, 2002 – March 8, 2005 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

CERTAIN 2002-2005 MY THOMAS BUILT MINOTOUR, CONVENTIONAL, MVP-ER, ER, HDX, AND MVP-EF MODEL SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 8, 2002, AND MARCH 8, 2005, EQUIPPED WITH SPECIALTY MFG "5" SERIES STOP ARMS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN STATES OTHER THAN THE FOLLOWING STATES: ALASKA, COLORADO, CONNECTICUT, DELAWARE, IDAHO, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, MONTANA, NEBRASKA, NEVADA, NEW HAMPSHIRE, NEW JERSEY, NEW MEXICO, NEW YORK, NORTH DAKOTA, OHIO, OREGON, PENNSYLVANIA, RHODE ISLAND, SOUTH DAKOTA, TENNESSEE, UTAH, VERMONT, VIRGINIA, WASHINGTON, WEST VIRGINIA, WISCONSIN, WYOMING, AND THE DISTRICT OF COLUMBIA. IN EXTREMELY COLD WEATHER, THE MICROSWITCHES USED INTERNALLY TO POSITION THE STOP ARM SIGN IN THE OPEN AND CLOSED POSITIONS MAY MALFUNCTION, CAUSING THE SIGN TO OPEN OR CLOSE IN AN IMPROPER POSITION, OR TO NOT OPEN AT ALL.

Safety consequence

SHOULD THE STOP ARM NOT PERFORM PROPERLY, A CHILD OR PEDESTRIAN MAY BE ENDANGERED BY PASSING VEHICLES SHOULD THE MOTORIST NOT STOP AT THE CORRECT LOCATION.

Manufacturer remedy

FOR THOSE BUSES OPERATED IN OR NEAR ANY OF THE STATES LISTED ABOVE, THOMAS BUILT IS ENCOURAGING THE BUS OWNERS TO OBTAIN THE REPLACEMENT SWITCH. FOR THOSE BUSES OPERATED IN THE WARMER STATES, DEALERS WILL REPLACE THE SWITCH UPON OWNER REQUEST. FOR THOSE CUSTOMERS WHO REQUEST THE REMEDY, THOMAS BUILT WILL REPLACE THE ORIGINAL SWITCH WITH A SWITCH PACK THAT IS NOT SENSITIVE TO EXTREME COLD WEATHER AND WILL INSPECT TO ENSURE THE MICROSWITCH HEATER WIRING IS PROPERLY CONNECTED. THE RECALL BEGAN ON SEPTEMBER 14, 2005. OWNERS MAY CONTACT THOMAS BUILT'S CUSTOMER SUPPORT OFFICE AT 336-889-4871.

Notes

THIS ACTION IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN AND IS NOT BEING CONDUCTED UNDER THE SAFETY ACT.FREIGHTLINER/THOMAS BUILT RECALL NO. FL-454.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.

STOP ARM MALFUNCTIONS

NHTSA #05V340000 · Other — School Bus Stop Arm Assembly · NHTSA notice

Reported July 25, 2005 · FREIGHTLINER LLC

Potentially affected: 13,583 vehicles

Manufacturer campaign FL-454 · Owners notified September 14, 2005 · Vehicles built January 8, 2002 – March 8, 2005 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

CERTAIN 2002-2005 MY THOMAS BUILT MINOTOUR, CONVENTIONAL, MVP-ER, ER, HDX, AND MVP-EF MODEL SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 8, 2002, AND MARCH 8, 2005, EQUIPPED WITH SPECIALTY MFG "5" SERIES STOP ARMS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: ALASKA, COLORADO, CONNECTICUT, DELAWARE, IDAHO, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, MONTANA, NEBRASKA, NEVADA, NEW HAMPSHIRE, NEW JERSEY, NEW MEXICO, NEW YORK, NORTH DAKOTA, OHIO, OREGON, PENNSYLVANIA, RHODE ISLAND, SOUTH DAKOTA, TENNESSEE, UTAH, VERMONT, VIRGINIA, WASHINGTON, WEST VIRGINIA, WISCONSIN, WYOMING, AND THE DISTRICT OF COLUMBIA. IN EXTREMELY COLD WEATHER, THE MICROSWITCHES USED INTERNALLY TO POSITION THE STOP ARM SIGN IN THE OPEN AND CLOSED POSITIONS MAY MALFUNCTION, CAUSING THE SIGN TO OPEN OR CLOSE IN AN IMPROPER POSITION, OR TO NOT OPEN AT ALL.

Safety consequence

SHOULD THE STOP ARM NOT PERFORM PROPERLY, A CHILD OR PEDESTRIAN MAY BE ENDANGERED BY PASSING VEHICLES SHOULD THE MOTORIST NOT STOP AT THE CORRECT LOCATION.

Manufacturer remedy

THOMAS BUILT WILL NOTIFY ITS OWNERS AND REPLACE THE ORIGINAL SWITCH WITH A SWITCH PACK THAT IS NOT SENSITIVE TO EXTREME COLD WEATHER AND WILL INSPECT TO ENSURE THE MICROSWITCH HEATER WIRING IS PROPERLY CONNECTED FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2005. OWNERS MAY CONTACT THOMAS BUILT'S CUSTOMER SUPPORT OFFICE AT 336-889-4871.

Notes

FREIGHTLINER/THOMAS BUILT RECALL NO. FL-454.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.

JOHN DEERE/ENGINE SURGE

NHTSA #05V208000 · Vehicle Speed Control · NHTSA notice

Reported April 27, 2005 · FREIGHTLINER LLC

Potentially affected: 153 vehicles

Manufacturer campaign FL-450 · Vehicles built November 1, 2002 – February 28, 2005 (per NHTSA)

Defect description

CERTAIN MY 2002-2005 THOMAS BUILT SAF-T-LINER ER SCHOOL BUSES AND ER TRANSIT BUSES MANUFACTURED BETWEEN NOVEMBER 2002 AND FEBRUARY 2005 AND EQUIPPED WITH JOHN DEERE 8.1L COMPRESSED NATURAL GAS ENGINES MODELS HFN01 AND HFN03. THE ENGINE CONTROL UNIT AND THROTTLE CAN UNEXPECTEDLY SURGE. THESE UNITS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 124, ACCELERATOR CONTROL SYSTEMS.

Safety consequence

A SUDDEN ENGINE SURGE COULD POSSIBLY RESULT IN A VEHICLE CRASH.

Manufacturer remedy

JOHN DEERE WILL NOTIFY THE CUSTOMERS OF FREIGHTLINER/THOMAS BUILT AND WILL UPDATE THE ENGINE CONTROL UNIT SOFTWARE FREE OF CHARGE. OWNERS MAY CONTACT JOHN DEERE AT 1-800-JD-ENGINE.

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.

Other Thomas ER model years

Check your 2003 Thomas ER VIN

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

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