FL981 – AC Electrical Connection May Overheat – 2024 Thomas Built Buses SAF-T-Liner C2 School Buses

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September 6, 2023 NHTSA CAMPAIGN NUMBER: 23V621000

AC Electrical Connection May Overheat

An overheated electrical connection increases the risk of a fire.

 

NHTSA Campaign Number: 23V621

Manufacturer Daimler Trucks North America, LLC

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 259

 

Summary

Daimler Trucks North America, LLC (DTNA) is recalling certain 2024 Thomas Built Buses SAF-T-Liner C2 school buses. The electrical cables for the air conditioning (AC) may not be installed properly, which can allow the electrical connection to overheat.

 

Remedy

Dealers will inspect and tighten the electrical cables, as necessary, free of charge. Owner notification letters are expected to be mailed October 6, 2023. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL981.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check for Daimler Trucks North America Recalls

 


Date: 9/7/2023

The Dealer Network is informed that a SAFETY RECALL NOTIFICATION has been sent to NHTSA notifying them of an approved DTNA vehicle Recall Campaign:

FL981: TBB SAF-T-LINER C2 AC Electrical Wiring

NHTSA#: TBD

Make: Thomas Built Buses
Model: SAF-T-LINER C2
Model Year: 2024
Manufacture Dates: May 1, 2023 – August 31, 2023

At Issue: The affected vehicles are equipped with factory installed Air Conditioners that include A/C components where the electrical cables may be loose or improperly installed. If the A/C electrical cables are loose or improperly installed, when the A/C is in use, this may lead to excessive heat buildup at the electrical connection which can increase the risk of a vehicle fire.

Reason for this Action: In an abundance of caution, DTNA will contact the Customer of Record on the suspect population, ahead of mailing the Final Recall Notification, to advise the Customer to contact their Servicing Dealer to have their vehicle visually inspected to determine if the defect is evident on the vehicle (see attached defect inspection procedure).

Remedy Description: DTNA will inspect the A/C electrical cables on the affected vehicles. If the electrical cables are found to be loose or improperly installed, they will be properly fastened or reinstalled with sufficient torque. Repairs will be performed free of charge by Daimler Truck North America authorized service facilities.

Remedy Availability: The remedy is available as of 9/7/2023. Please see attached Inspection and Work Instructions.

Notice: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. Some of the vehicles subject to this “Stop Delivery Order” may be in your new vehicle inventory. Until further instructions are available, new vehicles subject to this “Stop Delivery Order” must be held and not be delivered to customers.

Required Action: The Dealer Network is to inspect the vehicle. If the defect is found the Dealer is to contact the TBB Customer Assistance Center (1-855-253-0419) for instructions on how to return the vehicle to service, as well as the documentation of vehicle’s inspection.

 


Inspection and Work Instructions

Subject: TBB SAFTLINER C2 A/C Electrical Wiring

Models Affected: Specific model year 2024 Thomas Built Buses Saf-T-Liner C2 school buses, manufactured May 1, 2023, through August 31, 2023.

 

Problem: The affected vehicles are equipped with factory installed Air Conditioners that include A/C components where the electrical cables may be loose or improperly installed. If the A/C electrical cables are loose or improperly installed, when the A/C is in use, this may lead to excessive heat buildup at the electrical connection which can increase the risk of a vehicle fire.

Shop Safety Requirements: In order to perform any repairs in your shop, pay close attention to the following safety requirements.

  • Ensure that personal protective equipment is worn per Company
  • Set the parking
  • Remove the ignition key
  • Chock front and rear wheels on a level surface
  • Turn battery disconnect switch to the off position

 

Inspection and Work Procedure:

Ground studs – front side evaporator: Remove 2 square head screws that hold in place the glove box inner liner located left of driver side overhead compartment. Check nut on the grounding stud for tightness. If loose, tighten (recommended torque 95 in-lbs). If the ground stud happens to break, move the ground to a separate stud. If the nut was not tight, inspect the wiring for any damage – if there is damage to the ground wire, contact TBB for further guidance.

 

Ground stud – rear evaporator: Remove 2-3 phillips style screws from brackets holding plastic curtain molding to be able to pull the curtain molding away enough to expose the metal header with the ground studs. Check nut on the grounding stud for tightness. If loose, tighten (recommended torque 95 in-lbs). If the ground stud happens to break, move the ground to a separate stud. If the nut was not tight, inspect the wiring for any damage – if there is damage to the ground wire, contact TBB for further guidance.

 

Connections inside A/C box: Open the cover of the first door behind the battery compartment. Check for tightness of nuts attaching cables to the BCC control modules. Recommended torque is 95 in-lbs on the B (+) connectors between the cables and the megafuses. Check all connections to the bus bar on the control modules – joints should not be loose – torque nuts connecting wires to bus bar to 24-32 in-lbs if loose. Check all crimped connection joints – wires should be firm

 


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Chronology :

On or about August 16, 2023, DTNA was notified of a fire on a vehicle that was recently put into service. DTNA inspected the vehicle and found that the fire appeared to originate in or near the driver overhead console and occurred while the A/C was in use. A closer examination of the A/C electrical cable on this vehicle indicated the presence of a loose cable connection. Additional vehicles recently delivered to the same customer facility were examined and some were also found to have loose A/C electrical cables. DTNA also examined other recently built vehicles at the manufacturing facility and found additional vehicles with loose or improperly installed A/C electrical cables. DTNA’s investigation that revealed that each of the vehicles with a loose or improperly installed electrical cable had the A/C components installed outside of the normal production process. On September 5, 2023, out of abundance of caution, DTNA decided to conduct a voluntary safety recall on certain TBB Saf-T-Liner C2 vehicles built within the above-mentioned manufacturing date range, that were equipped with factory installed A/C components that were installed outside of the normal production process. The summary of warranty claims, field or service reports, and other information is as follows: 0 warranty claims and 1 Field report. No deaths or injuries reported.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
THOMAS BUILT BUSES SAF-T-LINER C2 2024

 


4 Associated Documents

Defect Notice 573 Report

RCLRPT-23V621-9699.PDF 214.251KB

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Recall Acknowledgement

RCAK-23V621-3826.pdf 645.248KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V621-2484.pdf 1204.868KB

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Recall 573 Report – September 7, 2023

RCLRPT-23V621-2810.PDF 214.378KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V621&docType=RCL

 


 

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