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NHTSA vehicle safety data

2004 Thomas MVP EF Recalls & Complaints

The 2004 Thomas MVP EF 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 dealer.

NHTSA recall and complaint data for the 2004 Thomas MVP EF. Recall data is refreshed daily from NHTSA.

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

2004 Thomas MVP EF owner complaints

Owners have filed 1 complaint with NHTSA about the 2004 Thomas MVP EF, describing incidents dated March 20, 2007.

Most-cited components

  • Engine 1 complaint
  • Structure 1 complaint

Newest complaints

  • ODI #10186403 · Filed

    PRE-2005 THOMAS 84 PASSENGER EF SCHOOL BUSES, WITH CAT C7 ENGINES/MD-3060 TRANSMISSIONS. FAILURE OF RIGHT/REAR ENGINE MOUNT CAUSES ENGINE TO REST IN RIGHT FRAME RAIL, SUPPORTED BY ALTERNATOR, WITH ENGINE FAN COMING IN CONTACT WITH RADIATOR SCHROUD. POST-2005 BUSES CAME WITH A REINFORCED MOUNT (REF…

Read the full complaint

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Thomas MVP EF in 2 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

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.

CUMMINS ECM FUEL SYSTEM LIFT PUMP

NHTSA #05V469000 · Fuel System, Other — Delivery — Fuel Pump · NHTSA notice

Reported October 5, 2005 · FREIGHTLINER LLC

Potentially affected: 8,310 vehicles

Manufacturer campaign FL-463 · Vehicles built January 1, 2004 – May 31, 2005 (per NHTSA)

Defect description

CERTAIN 2004 AND 2005 FREIGHTLINER VAN, MOTOR HOME, SHUTTLE BUS, AND SCHOOL BUS CHASSIS MANUFACTURED BETWEEN JANUARY 2004 AND MAY 2005. ERRATIC VOLTAGE SUPPLY TO THE FUEL LIFT PUMP CAUSES PREMATURE WEAR OF THE PUMP. THIS PREMATURE WEAR COULD RESULT IN FUEL LIFT PUMP FAILURE AND IN SOME CASES MAY CAUSE AN ENGINE STALL CONDITION.

Safety consequence

SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.

Manufacturer remedy

CUMMINS WILL NOTIFY THE OWNERS OF THE FREIGHTLINER AND THOMAS BUILT VEHICLES AND WILL REPAIR THE ENGINES BY EMC RECALIBRATION AND REPLACEMENT OF THE FUEL LIFT PUMP AT NO CHARGE TO THE CUSTOMER. OWNERS MAY CONTACT CUMMINS ASSISTANCE CENTER 1-800-DIESELS (1-800-343-7357) OR FREIGHTLINER AT 1-800-547-0712.

Notes

FREIGHTLINER RECALL NO. FL-463.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.

DANA TIE ROD ASSEMBLIES

NHTSA #05V137000 · Steering — Linkages — Tie Rod Assembly · NHTSA notice

Reported April 1, 2005 · FREIGHTLINER LLC

Potentially affected: 4,819 vehicles

Manufacturer campaign FL-441 · Owners notified September 6, 2005 · Vehicles built September 24, 2000 – March 4, 2004 (per NHTSA)

Defect description

CERTAIN 2001-2004 MY THOMAS BUILT MVP-EF, ER TRANSIT, MVP-ER, HD, AND HDX SCHOOL BUSES MANUFACTURED BETWEEN SEPTEMBER 24, 2000, AND MARCH 4, 2004. THE TIE ROD ASSEMBLY CAN FRACTURE AND FAIL, POSSIBLY RESULTING IN COMPLETE SEPARATION.

Safety consequence

TIE ROD FAILURE CAN POSSIBLY RESULT IN COMPLETE WHEEL SEPARATION AND A VEHICLE CRASH COULD OCCUR.

Manufacturer remedy

THOMAS BUILT WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE TIE ROD ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN SEPTEMBER 6, 2005. OWNERS MAY CONTACT THOMAS BUILT AT (WE DO NOT YET HAVE A TELEPHONE NUMBER).

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.

MICHELIN/RAPID AIR LOSS

NHTSA #04T023000 · Tires · NHTSA notice

Reported December 22, 2004 · MICHELIN NORTH AMERICA, INC.

Potentially affected: 4,000 vehicles

Owners notified December 27, 2004

Defect description

CERTAIN MICHELIN XDE COMMERCIAL TRUCK TIRES, SIZE 10R22.5 LRG AND LRF FOR USE ON FREIGHTLINER SCHOOL AND TRANSIT BUSES. THESE TIRES WERE MANFACTURED BETWEEN MAY 23 AND OCTOBER 24, 2004, CAN EXPERIENCE RAPID AIR LOSS DUE TO AN IRREGULARITY OF THE INNER LINER.

Safety consequence

RAPID AIR LOSS CAN RESULT IN LOSS OF VEHICLE CONTROL AND A VEHICLE CRASH CAN OCCUR.

Manufacturer remedy

MICHELIN WILL NOTIFY ITS CUSTOMERS AND REPLACE THE TIRES FREE OF CHARGE. THE RECALL BEGAN DECEMBER 27, 2004. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT MICHELIN AT 888-622-2306.

Notes

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

Other Thomas MVP EF model years

Check your 2004 Thomas MVP EF VIN

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

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