RecallRepo

1991 Thomas Built Saf-T-Liner Recalls

Recalls on record Updated July 2026

The 1991 Thomas Built Saf-T-Liner has 5 NHTSA recall campaigns affecting an estimated 154,473 vehicles. Recall repairs are always free at any authorized dealer. Last updated July 5, 2026.

Recall campaigns

ELECTRICAL SYSTEM 97V133000 1997-08-22 8,107 affected
Defect

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH IN-LINE SIX ENGINE,"S" TYPE FRAME RAILS AND SIDE MOUNTED BATTERY BOX. THE BATTERY CABLE ROUTING ALLOWS THE POSITIVE CABLE TO CHAFE RESULTING IN A POSSIBLE SHORT CIRCUIT OF THE CABLE.

Consequence

IF AN ELECTRICAL SHORT OCCURS, IT CAN CAUSE LOSS OF POWER TO THE VEHICLE AND A POSSIBLE VEHICLE FIRE.

Remedy

THOMAS BUILT WILL PROVIDE OWNERS WITH REPAIR PARTS AND DETAILED REPAIR PROCEDURES TO SECURE THE CABLE TO PREVENT FURTHER DAMAGE. IF THE OWNER SO DESIRES, THOMAS BUILT WILL PERFORM THE REPAIR FOR THEM.

SERVICE BRAKES, AIR 97V030000 1997-03-03 695 affected
Defect

CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM CAN RESULT IN DAMAGE TO THE BRAKE CHAMBER CLAMP BAND.

Consequence

IF THE DAMAGE TO THE CLAMP BAND RESULTED IN BAND BREAKAGE, THE CHAMBER COULD COME APART RESULTING IN LOSS OF THE SERVICE BRAKES. THE EMERGENCY BRAKES WOULD AUTOMATICALLY APPLY.

Remedy

DEALERS WILL INSPECT THE BRAKE CHAMBER FOR SIGNS OF CONTACT. IF CONTACT IS INDICATED, THE BRAKE CAM SHAFT AND CHAMBER SUPPORT BRACKET WILL BE REPLACED, ELIMINATING THE POSSIBILITY OF CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM.

STRUCTURE 96V139000 1996-07-23 120,371 affected
Defect

AN ITEM WORN BY A CHILD, SUCH AS A LONG DRAWSTRING, SASH, OR BACKPACK/BOOKBAG ACCESSORY, CAN BECOME CAUGHT IN THE AREA BETWEEN THE SERVICE DOOR AND THE DOOR CONTROL ROD ATTACHING BRACKET.

Consequence

IF AN ITEM WORN BY A CHILD WERE TO CATCH ON THIS AREA, AND THE DRIVER WERE TO CLOSE THE DOOR AND PUT THE VEHICLE IN MOTION, THIS CAN RESULT IN SERIOUS INJURY OR DEATH.

Remedy

A MOLDED COVER WILL BE INSTALLED BETWEEN THE MANUALLY OPERATED OUTWARD OPENING ENTRANCE DOOR AND THE DOOR CONTROL ROD ATTACHING BRACKET WHICH WILL ELIMINATE THE OPENING THAT COULD ALLOW AN ITEM OF A CHILD'S CLOTHING TO BECOME SNAGGED.

SERVICE BRAKES, AIR 96V021000 1996-01-29 730 affected
Defect

CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM CAN RESULT IN DAMAGE TO THE BRAKE CHAMBER CLAMP BAND.

Consequence

IF THE DAMAGE TO THE CLAMP BAND RESULTED IN BAND BREAKAGE, THE CHAMBER COULD COME APART RESULTING IN LOSS OF THE SERVICE BRAKES. THE EMERGENCY BRAKES WOULD AUTOMATICALLY APPLY.

Remedy

DEALERS WILL INSPECT THE BRAKE CHAMBER FOR SIGN OF CONTACT. IF CONTACT IS INDICATED, THE BRAKE CAM SHAFT AND CHAMBER SUPPORT BRACKET WILL BE REPLACED, ELIMINATING THE POSSIBLITY OF CONTACT BETWEEN THE BRAKE CHAMBER AND THE SUSPENSION BEAM.

VISIBILITY 93V013000 1993-01-01 24,570 affected
Defect

THE CURRENT PRODUCTION STATIONARY WINDOW ASSEMBLIES ALLOW THE GLASS TO DISENGAGE FROM THE RUBBER AND/OR FRAME.

Consequence

THE WINDOWS DO NOT COMPLY WITH FMVSS 217, "BUS WINDOWRETENTION AND RELEASE."

Remedy

INSTALL TWO RETAINING CLIPS AT EACH NON-COMPLYING WINDOW.

Defect investigations

Investigation PE92035 Opened 1992-03-30 · closed 1992-08-20

AXLE/UNIVER.YOKE FAILURE

There is no summary currently available

Investigation PE94025 Opened 1994-03-07 · closed 1994-04-20

BRAKE TREADLE VALVE CORRODES

There is no summary currently available

Sources & methodology

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 Saf-T-Liner as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.