The 1991 Thomas Built Bus has 6 NHTSA recall campaigns affecting an estimated 10,422 vehicles. Recall repairs are always free at any authorized dealer. Last updated July 5, 2026.
THE SAFETY BELT ANCHORAGE BOLTS DO NOT COMPLY WITH THE REQUIREMENTS OF FMVSS 210, "SEAT BELT ASSEMBLY ANCHORAGES". THE SEAT ANCHORAGES COULD NOT MAINTAIN LOAD OF 5,000 LBS FOR 10 SECONDS.
THE SAFETY BELTS MIGHT NOT ADEQUATELY PROTECT SEATOCCUPANTS IN THE EVENT OF A SUDDEN STOP OR ACCIDENT.
REPLACE THE ANCHORAGE BOLTS WITH BOLTS OF A LARGER DIAMETER, WHICH MEET THE LOAD REQUIREMENTS OF FMVSS 210.
INCORRECT SCREWS WERE USED TO ATTACH THE PLYWOOD SEAT BACK TO THE SEAT FRAME.
THE DRIVER'S SEAT BACK DOES NOT MEET THE STRENGTHREQUIREMENTS OF FMVSS 207, "SEATING SYSTEM". SHOULD THE SEAT BACK FAIL WHILETHE BUS IS IN MOTION, THE OPERATOR COULD LOSE CONTROL OF THE BUS.
REMOVE INCORRECT SCREWS ATTACHING THE PLYWOOD BACK TO THE SEAT FRAME AND INSTALL PROPER SCREWS.
THE DRIVESHAFT USED WITH SOME ENGINE/TRANSMISSION COMBINATIONS HAD INSUFFICIENT WELDS JOINING SOME OF THE COMPONENTS.
THE BAD WELDS CAN DEVELOP CRACKS THAT CAN CAUSE COMPLETESEPARATION OF THE DRIVESHAFT. THIS CAN RESULT IN LOSS OF MOTIVE POWER FOR THEVEHICLE AND POSSIBLE LOSS OF VEHICLE CONTROL.
REPLACE DEFECTIVE NORTH AMERICAN DRIVESHAFTS WITH SPICER DRIVESHAFTS.
THE CENTER ACTUATOR THAT RELEASES TWO CATCHES VIA TWO PULL RODS CAN BECOME NON-FUNCTIONAL FROM POOR OR IMPROPER MAINTENANCE, LACK OF LUBRICATION, CORROSION, OR A COMBINATION ALL THREE CAUSES.
WHEN THE CENTER ACTUATOR IS NON-FUNCTIONAL, THE WINDOWIS VERY DIFFICULT TO OPEN, AND WOULD NOT FUNCTION AS AN EMERGENCY EXIT IN CASEOF A VEHICULAR ACCIDENT.
REMOVE THE OLD CENTER ACTUATOR AND INSTALL AN IMPROVED ACTUATOR.
THE FUEL SHUT-OFF SOLENOID IN THE CUMMINS 6C ENGINE MAY BE FAULTY, CAUSING SPONTANEOUS INTERRUPTION OF FUEL FLOW TO THE ENGINE DURING NORMAL OPERATION. THIS RESULTS IN LOSS OF POWER TO DRIVING WHEELS, POWER STEERING, AND OTHER POWER ASSISTED OPERATING SYSTEMS.
LOSS OF ENGINE POWER AND SECONDARY LOSS OF POWER ASSISTEDSYSTEMS REDUCES STEERING CONTROL, BRAKING ABILITY, VISUAL SYSTEMS AND OTHERPOWER ASSISTED OPERATING SYSTEMS, RESULTING IN INCREASED RISK OF VEHICLEACCIDENT.
WHERE NECESSARY, REPLACE THE SOLENOID SPRING, ADJUST SOLENOID, REPLACE WIRES, AND VERIFY MAXIMUM POWER REQUIREMENTS TO THE SOLENOID.
THE STEERING LINKAGE (DRAG LINK) BETWEEN THE STEERING GEAR PITMAN ARM AND THE STEERING ARM ON THE AXLE MAY HAVE BEEN IMPROPERLY FASTENED.
THE DRAG LINK COULD BECOME DISCONNECTED AT EITHER ENDWHICH RESULTS IN LOSS OF STEERING CONTROL AND THE POTENTIAL FOR AN ACCIDENT.
INSTALL CORRECT PINS AND PROPERLY TIGHTEN THE CASTELLATED NUTS.
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Thomas Built Bus as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.