NHTSA vehicle safety data

2005 Thomas SAF-T-Liner ER Recalls & Complaints

The 2005 Thomas SAF-T-Liner ER has 1 NHTSA recall campaign and 2 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Thomas dealer.

NHTSA recall and complaint data for the 2005 Thomas SAF-T-Liner ER. Recall data is refreshed daily from NHTSA.

2005 Thomas SAF-T-Liner ER owner complaints

Owners have filed 2 complaints with NHTSA about the 2005 Thomas SAF-T-Liner ER, describing incidents dated January 22, 2006 to February 26, 2006.

Most-cited components

Electrical System 2 complaints

Of the 2 complaints on file, 2 report a fire (owner-reported, not verified by NHTSA).

Newest complaints

ODI #10183520 · Filed February 26, 2007
PRINTED CIRCUIT BOARD OVERHEATS AND CATCHES FIRE. THIS PROBLEM HAS OCCURRED BEFORE AND WE HAVE HAD A 50% FAILURE RATE ON THIS MODEL BUS. THIS PART IS COVERED UNDER RECALL 06V-136 BUT DOES NOT COVER THE MANUFACTURE DATE OF THIS BUS. *NM
ODI #10183518 · Filed February 26, 2007
PRINTED CIRCUIT PANEL LOCATED UNDER SIDE PANEL OF BUS OVERHEATED AND HAD A SMALL FIRE. THIS PROBLEM IS COVERED UNDER RECALL 06V-136 BUT DOES COVER THIS PARTICULAR VEHICLE. IT APPEARS THAT THIS RECALL NEEDS TO BE EXPANDED TO COVER MORE VEHICLES, WE HAVE HAD A 50% FAILURE RATE OF THIS PARTICULAR…

Read all 2 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2005 Thomas SAF-T-Liner 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.

Engineering Analysis EA07-002: STEERING COLUMN WELD CRACKS
Closed July 12, 2007
- Recall 07V-289

Open and recently closed NHTSA defect investigations

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.

try.vin has no NCAP crash-test rating on file for the 2005 Thomas SAF-T-Liner ER. 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 2005 Thomas SAF-T-Liner ER.

Electrical System

ODI #10183520

Fire

Incident: February 26, 2006 · Filed: February 26, 2007

PRINTED CIRCUIT BOARD OVERHEATS AND CATCHES FIRE. THIS PROBLEM HAS OCCURRED BEFORE AND WE HAVE HAD A 50% FAILURE RATE ON THIS MODEL BUS. THIS PART IS COVERED UNDER RECALL 06V-136 BUT DOES NOT COVER THE MANUFACTURE DATE OF THIS BUS. *NM

Electrical System

ODI #10183518

Fire

Incident: January 22, 2006 · Filed: February 26, 2007

PRINTED CIRCUIT PANEL LOCATED UNDER SIDE PANEL OF BUS OVERHEATED AND HAD A SMALL FIRE. THIS PROBLEM IS COVERED UNDER RECALL 06V-136 BUT DOES COVER THIS PARTICULAR VEHICLE. IT APPEARS THAT THIS RECALL NEEDS TO BE EXPANDED TO COVER MORE VEHICLES, WE HAVE HAD A 50% FAILURE RATE OF THIS PARTICULAR COMPONENT. *NM

Other Thomas SAF-T-Liner ER model years

Check your 2005 Thomas SAF-T-Liner ER VIN

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

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