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November 2, 2021 NHTSA CAMPAIGN NUMBER: 21V850000
Alternator Power Cable Connection May be Loose
A loose power cable connection may cause electrical arcing, which can increase the risk of a fire.
NHTSA Campaign Number: 21V850
Manufacturer Daimler Trucks North America, LLC
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 1,434
Summary
Daimler Trucks North America, LLC (DTNA) is recalling certain 2020-2022 Thomas Built EFX and HDX school buses. The nut for the power cable stud on the alternator may not have been tightened properly, which can cause a loose cable connection.
Remedy
Dealers will inspect the alternator power cable connection and tighten it if necessary, free of charge. Owner notification letters were mailed on December 17, 2021. Owners may contact DTNA customer service at 1-800-547-0712. DTNA’s number for this recall is FL904.
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.
Subject: TBB Alternator Cable Loose
Models Affected: Specific model year 2020-2022 Thomas Built Buses EFX and HDX vehicles manufactured October 1, 2019, through August 19, 2021.
General Information
Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Thomas Built Buses (TBB), has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above.
On certain EFX & HDX model school busses, the nut for the power cable stud on the alternator may not have been torqued properly. A loose cable connection on an unfused power cable may increase the risk of a fire.
The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by DTNA authorized service facilities.
There are approximately 1,451 vehicles involved.
Additional Repairs
Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns before sale or delivery of a vehicle.
Owners may be liable for any progressive damage that results from failure to complete campaigns within a reasonable time after receiving notification.
Please contact Warranty Campaigns for consideration of additional charges prior to performing the repair.
Work Instructions
Please refer to the attached work instructions.
Replacement Parts
There are no replacement parts.
Chronology :
At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue.
In February 2022, NHTSA asked for updated information on warranty claims, field service reports, and other things such as the number of deaths and injuries. The response is:
- In July 2021, DTNA received a dealer notification, described above. Also that month, DTNA received seven claims, within the 17 cited above.
- In August 2021, DTNA discovered five claims where the alternator cable was loose or detached from the power stud on the alternator, as part of the investigation described above.
- In September 2021, DTNA received three additional claims, also within the 17 cited above.
- Subsequent warranty searches revealed other claims, with potentially similar failure modes although the link cannot be verified–one in December 2020 and another in March of 2021.
- There were no injuries or deaths reported.
6 Affected Products
Vehicles
MAKE | MODEL | YEAR |
THOMAS BUILT BUSES | SAF-T-LINER EFX | 2020-2022 |
THOMAS BUILT BUSES | SAF-T-LINER HDX | 2020-2022 |
14 Associated Documents
Manufacturer Notices(to Dealers,etc)
RCMN-21V850-8523.pdf 965.417KB
Recall Acknowledgement
RCAK-21V850-7434.pdf 652.216KB
Recall 573 Report – Amendment 1
RCLRPT-21V850-3876.PDF 214.029KB
Defect Notice 573 Report
RCLRPT-21V850-2839.PDF 214.055KB
Miscellaneous Document- Defect Information Report
RMISC-21V850-2812.pdf 727.183KB
Miscellaneous Document – Amended DIR
RMISC-21V850-8972.pdf 639.15KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V850-0544.pdf 146.989KB
Recall 573 Report – Amendment 2
RCLRPT-21V850-8676.PDF 214.026KB
Recall Quarterly Report #1, 2021-4
RCLQRT-21V850-1472.PDF 211.152KB
Miscellaneous Document
RMISC-21V850-4098.pdf 703.984KB
Recall Quarterly Report #2, 2022-1
RCLQRT-21V850-5454.PDF 211.253KB
Recall Quarterly Report #3, 2022-2
RCLQRT-21V850-6204.PDF 211.333KB
Recall 573 Report – 2/11/22
RCLRPT-21V850-3115.PDF 214.459KB
Recall Quarterly Report #4, 2022-3
RCLQRT-21V850-9845.PDF 211.446KB
Latest Recalls Documents
For the Latest and Most Recent Recalls Information Visit the link below…
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V850&docType=RCL
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SEOCONTENT-START
Defect Information Report (Section 573.6) FL-904 Date of Submission: November 03, 2021 Manufacturer: Daimler Trucks North America LLC P.O. BOX 3849 Portland, Oregon 97208 Type of Report: X Safety Defect ⃝ Non-Compliance Vehicle Information Model Yr. Start: 2020 Model Yr. End: 2022 Make: Thomas Built Buses Model: Saf-T-Liner HDX, Saf-T-Liner EFX Production Dates: Begin: 10/01/2019 End: 08/19/2021 Descriptive Information: Certain EFX & HDX model school busses manufactured 10/01/2019 and 08/19/2021. Number potentially involved: 1434 Estimated percentage of involve with defect: 1% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. Describe the safety risk: Arcing due to a loose cable connection on an unfused power cable may increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Identify any warning which can precede or occur: The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. If applicable, identify the manufacture of the defective or noncompliant component.: N/A There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Involved Components Component Name: Nut Component Description: NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number: 23-13861-105 Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Identify the Recall Schedule Describe the recall schedule for notifications.: Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Begin Date: 12/27/2021 Planned Dealer Notification End Date: 12/27/2021 Planned Owner Notification Begin Date: 12/27/2021 Planned Owner Notification End Date: 12/27/2021 Manufacture’s identification code for this recall (if applicable): FL-904 DTNA Representative; Tiffani Torgeson Manager, Compliance and Regulatory Affairs
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Defect Information Report (Section 573.6) FL-904 Date of Submission: February 11, 2021 Manufacturer: Daimler Truck North America LLC P.O. BOX 3849 Portland, Oregon 97208 Type of Report: X Safety Defect ⃝ Non-Compliance Vehicle Information Model Yr. Start: 2020 Model Yr. End: 2022 Make: Thomas Built Buses Model: Saf-T-Liner HDX, Saf-T-Liner EFX Production Dates: Begin: 10/01/2019 End: 08/19/2021 Descriptive Information: Certain EFX & HDX model school busses manufactured 10/01/2019 and 08/19/2021. Number potentially involved: 1434 Estimated percentage of involve with defect: 1% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. Describe the safety risk: Arcing due to a loose cable connection on an unfused power cable may increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Identify any warning which can precede or occur: The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. If applicable, identify the manufacture of the defective or noncompliant component.: N/A There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Involved Components Component Name: Nut Component Description: NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number: 23-13861-105 Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. In February 2022, NHTSA asked for updated information on warranty claims, field service reports, and other things such as the number of deaths and injuries. The response is: In July 2021, DTNA received a dealer notification, described above. Also that month, DTNA received seven claims, within the 17 cited above. In August 2021, DTNA discovered five claims where the alternator cable was loose or detached from the power stud on the alternator, as part of the investigation described above. In September 2021, DTNA received three additional claims, also within the 17 cited above. Subsequent warranty searches revealed other claims, with potentially similar failure modes although the link cannot be verified–one in December 2020 and another in March of 2021. There were no injuries or deaths reported. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Identify the Recall Schedule Describe the recall schedule for notifications.: Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Begin Date: 12/27/2021 Planned Dealer Notification End Date: 12/27/2021 Planned Owner Notification Begin Date: 12/27/2021 Planned Owner Notification End Date: 12/27/2021 Manufacture’s identification code for this recall (if applicable): FL-904 DTNA Representative; Tiffani Torgeson Manager, Compliance and Regulatory Affairs
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Defect Information Report (Section 573.6) FL-904 Date of Submission: November 03, 2021 Manufacturer: Daimler Trucks North America LLC P.O. BOX 3849 Portland, Oregon 97208 Type of Report: X Safety Defect ⃝ Non-Compliance Vehicle Information Model Yr. Start: 2020 Model Yr. End: 2022 Make: Thomas Built Buses Model: Saf-T-Liner HDX, Saf-T-Liner EFX Production Dates: Begin: 10/01/2019 End: 08/19/2021 Descriptive Information: Certain EFX & HDX model school busses manufactured 10/01/2019 and 08/19/2021. Number potentially involved: 1434 Estimated percentage of involve with defect: 1% Defect / Noncompliance Description For this Defect/Noncompliance: Describe the defect or noncompliance: On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. Describe the safety risk: Arcing due to a loose cable connection on an unfused power cable may result in a loss of power or, in the extreme, increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Identify any warning which can precede or occur: The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. If applicable, identify the manufacture of the defective or noncompliant component.: N/A There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Involved Components Component Name: Nut Component Description: NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number: 23-13861-105 Chronology of Defect / Noncompliance Determination Provide the chronology of events leading up to the defect decision or test data for the noncompliance decision: At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. Identify the Remedy Describe the defect/noncompliance remedy program, including the manufacture’s plan for reimbursement. The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Identify the Recall Schedule Describe the recall schedule for notifications.: Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Begin Date: 12/27/2021 Planned Dealer Notification End Date: 12/27/2021 Planned Owner Notification Begin Date: 12/27/2021 Planned Owner Notification End Date: 12/27/2021 Manufacture’s identification code for this recall (if applicable): FL-904 DTNA Representative; Tiffani Torgeson Manager, Compliance and Regulatory Affairs
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Daimler Trucks North America LLC December 2021 FL904 AB NHTSA # 21V-850 (School Bus) IMPORTANT SAFETY RECALL See enclosed VIN list Subject: TBB Alternator Cable Loose This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary Thomas Built Buses, has decided that a defect that relates to motor vehicle safety exists on specific model years 2020-2022, EFX & HDX model school busses manufactured October 1, 2019, through August 19, 2021. On certain EFX & HDX model school busses, the nut for the power cable stud on the alternator may not have been torqued properly. A loose cable connection on an unfused power cable may increase the risk of a fire. The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Please contact an authorized Daimler Trucks North America dealer to arrange to have the Recall performed and to ensure that parts are available at the dealership. To locate an authorized dealer, search online at Daimler-TrucksNorthAmerica.com/Contact-us. Scroll down to “Locate a Dealer” and select the appropriate brand. The Recall will take approximately one hour and will be performed at no charge to you. You may also confirm your vehicle’s involvement in this recall at this URL: https://dtna-dlrinfo.prd.freightliner.com:48518/VinLookup/vin-module/getVinLookupPage. You may be liable for any progressive damage that results from your failure to complete the Recall within a reasonable time after receiving notification. If you do not own the vehicle that corresponds to the identification number(s) which appears on the Recall Notification, please return the notification to the Warranty Campaigns Department with any information you can furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law requires that you forward this notice to your distributors and retail outlets within five working days. If you have paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement. Please see the reverse side of this notice for details. If you have questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address DTNA.Warranty.Campaigns@Daimler.com. For other concerns, you may contact the Customer Assistance Center at (800) 385-4357. If you are not able to have the defect remedied without charge and within a reasonable time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue SE, Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236 (TTY: 800-424-9153); or go to http://www.safercar.gov. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. WARRANTY CAMPAIGNS DEPARTMENT Enclosure Daimler Trucks North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone Daimler Trucks North America LLC Reimbursement to Customers for Repairs Performed Prior to Recall If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement. Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Daimler Trucks North America LLC dealer. The following documentation must be presented to your dealer for consideration for reimbursement. Please provide original or clear copies of all receipts, invoices, and repair orders that show: • The name and address of the person who paid for the repair. • The Vehicle Identification Number (VIN) of the vehicle that was repaired. • What problem occurred, what repair was done, when the repair was done. • Who repaired the vehicle. • The total cost of the repair expense that is being claimed. • Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt). Reimbursement will be made by check from your Daimler Trucks North America LLC dealer. Please speak with your Daimler Trucks North America LLC authorized dealer concerning this matter Daimler Trucks North America LLC Warranty Campaigns Department P.O. Box 4090 Portland, OR 97208-4090 800.547.0712 Phone
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Daimler Trucks North America LLC Recall Campaign Page 1 December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) Subject: TBB Alternator Cable Loose Models Affected: Specific model year 2020-2022 Thomas Built Buses EFX and HDX vehicles manufactured October 1, 2019, through August 19, 2021. General Information Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Thomas Built Buses (TBB), has decided that a defect that relates to motor vehicle safety exists on the vehicles mentioned above. On certain EFX & HDX model school busses, the nut for the power cable stud on the alternator may not have been torqued properly. A loose cable connection on an unfused power cable may increase the risk of a fire. The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by DTNA authorized service facilities. There are approximately 1,451 vehicles involved. Additional Repairs Dealers must complete all outstanding Recall and Field Service campaigns prior to the sale or delivery of a vehicle. A Dealer will be liable for any progressive damage that results from its failure to complete campaigns before sale or delivery of a vehicle. Owners may be liable for any progressive damage that results from failure to complete campaigns within a reasonable time after receiving notification. Please contact Warranty Campaigns for consideration of additional charges prior to performing the repair. Work Instructions Please refer to the attached work instructions. Replacement Parts There are no replacement parts. If our records show your dealership has ordered any vehicle(s) involved in campaign number FL904, a list of the customers and vehicle identification numbers will be available on DTNAConnect. Removed Parts U.S. and Canadian Dealers, please follow Warranty Failed Parts Tracking shipping instructions for the disposition of all removed parts. Export distributors, please destroy removed parts unless otherwise advised. Daimler Trucks North America LLC Recall Campaign Page 2 December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) Labor Allowance Table 2 – Labor Allowance Campaign Number Procedure Time Allowed (hours) SRT Codes Corrective Action FL904A TIGHTEN ALTERNATOR POWER CABLE 0.9 996-R131A 12-Repair Recall/Campaign FL904B TIGHTEN ALTERNATOR POWER CABLE 0.8 996-R131B 12-Repair Recall/Campaign Claims for Credit Table 2 You will be reimbursed for your parts, labor, and handling (landed cost for Export Distributors) by submitting your claim through the Warranty system within 30 days of completing this campaign. Please reference the following information in OWL: • Claim type is Recall Campaign. • In the Campaign field, enter the campaign number and appropriate condition code (FL904-A or FL904-B). • In the Primary Failed Part field, enter 25-FL904-000. • In the Labor section, enter the appropriate SRT from the Labor Allowance Table. • The VMRS Component Code is F99-999-005 and the Cause Code is A1 – Campaign. • U.S. and Canada – Reimbursement for Prior Repairs. When a customer asks about reimbursement, please do the following: • Accept the documentation of the previous repair. • Make a brief check of the customer’s paperwork to see if the repair may be eligible for reimbursement. (See the “Copy of Owner Letter” section of this bulletin for reimbursement guidelines.) • Submit an OWL Recall Pre-Approval Request for a decision. • Include the approved amount on your claim in the Other Charges section. • Attach the documentation to the pre-approval request. • If approved, submit a based on claim for the pre-approval. • Reimburse the customer the appropriate amount. IMPORTANT: OWL must be viewed prior to performing the recall to ensure the vehicle is involved and the campaign has not been previously completed. Also, check for a completion sticker prior to beginning work. U.S. and Canadian dealers, contact the Warranty Campaigns Department via Web inquiry at DTNAConnect.com/WSC, if you have any questions or need additional information. Export distributors, submit a Web inquiry or contact your International Service Manager. U.S. and Canadian Dealers; To return excess kit inventory related to this campaign, U.S. dealers must submit a Parts Daimler Trucks North America LLC Recall Campaign Page 3 December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) Authorization Return (PAR) to the Memphis PDC. Canadian dealers must submit a PAR to their facing PDC. All kits must be in resalable condition. PAR requests must include the original purchase invoice number. Export Distributors: Excess inventory is not returnable. The letter notifying U.S. and Canadian vehicle owners is included for your reference Please note that the National Traffic and Motor Vehicle Safety Act, as amended (Title 49, United States Code, Chapter 301), requires the owner’s vehicle(s) be corrected within a reasonable time after parts are available to you. The Act states that failure to repair a vehicle within 60 days after tender for repair shall be prima facie evidence of an unreasonable time. However, circumstances of a particular situation may reduce the 60 day period. Failure to repair a vehicle within a reasonable time can result in either the obligation to (a) replace the vehicle with an identical or reasonably equivalent vehicle, without charge, or (b) refund the purchase price in full, less a reasonable allowance for depreciation. The Act further prohibits dealers from selling a vehicle unless all outstanding recalls are performed. Any lessor is required to send a copy of the recall notification to the lessee within 10 days. Any subsequent stage manufacturer is required to forward this notice to its distributors and retail outlets within five working days. Daimler Trucks North America LLC Recall Campaign Page 4 December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) Copy of Notice to Owners Subject: TBB Alternator Cable Loose For the Notice to U.S. Customers: This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. For the Notice to Canadian Customers: This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. This is to inform you that your vehicle may contain a defect that could affect the safety of a person. Daimler Trucks North America LLC (DTNA), on behalf of its wholly owned subsidiary, Thomas Built Buses, has decided that a defect that relates to motor vehicle safety exists on specific model years 2020-2022 EFX & HDX model school busses manufactured October 1, 2019, through August 19, 2021. The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by DTNA authorized service facilities. Please contact an authorized Daimler Trucks North America dealer to arrange to have the Recall performed. To locate an authorized dealer, go to www.Daimler-TrucksNorthAmerica.com. On the menu tab, select “Contact,” scroll down to “Find a Dealer,” and select the appropriate brand. The Recall will take approximately one hour and will be performed at no charge to you. You may also confirm your vehicle’s involvement in this recall at this URL: https://dtna-dlrinfo.prd.freightliner.com:48518/VinLookup/vin-module/getVinLookupPage. You may be liable for any progressive damage that results from your failure to complete the Recall within a reasonable time after receiving notification. If you do not own the vehicle that corresponds to the identification number(s), which appears on the Recall Notification, please return the notification to the Warranty Campaigns Department with any information you can furnish that will assist us in locating the present owner. If you have leased this vehicle, Federal law requires that you forward this notice to the lessee within 10 days. If you are a subsequent stage manufacturer, Federal law requires that you forward this notice to your distributors and retail outlets within five working days. If you have paid to have this recall condition corrected prior to this notice, you may be eligible to receive reimbursement. Please see the reverse side of this notice for details. If you have questions about this Recall, please contact the Warranty Campaigns Department at (800) 547-0712, 7:00 a.m. to 4:00 p.m. Pacific Time, Monday through Friday, e-mail address DTNA.Warranty.Campaigns@Daimler.com. For the Notice to U.S. Customers: If you are not able to have the defect remedied without charge and within a reasonable time, you may wish to submit a complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the Vehicle Safety Hotline at (888) 327-4236 (TTY: 800-424- 9153); or to http://www.safercar.gov. For the Notice to Canadian Customers: If you wish to submit a complaint about this recall, you can contact Transport Canada road safety, 80 rue Noel, Gatineau, Quebec J8Z 0A1 or call (800) 333- 0510. We regret any inconvenience this action may cause but feel certain you understand our interest in motor vehicle safety. WARRANTY CAMPAIGNS DEPARTMENT Enclosure Daimler Trucks North America LLC Recall Campaign Page 5 December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) Reimbursement to Customers for Repairs Performed Prior to Recall If you have already paid to have this recall condition corrected you may be eligible to receive reimbursement. Requests for reimbursement may include parts and labor. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Daimler Trucks North America LLC dealer. The following documentation must be presented to your dealer for consideration for reimbursement. Please provide original or clear copies of all receipts, invoices, and repair orders that show: • The name and address of the person who paid for the repair • The Vehicle Identification Number (VIN) of the vehicle that was repaired • What problem occurred, what repair was done, when the repair was done • Who repaired the vehicle • The total cost of the repair expense that is being claimed • Proof of payment for the repair (such as the front and back of a cancelled check or a credit card receipt) Reimbursement will be made by check from your Daimler Trucks North America LLC dealer. Please speak with your Daimler Trucks North America LLC authorized dealer concerning this matter. Daimler Trucks North America LLC Recall Campaign Page 6 December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) Work Instructions Subject: TBB Alternator Cable Loose Models Affected: Specific model year 2020-2022 Thomas Built Buses EFX and HDX vehicles manufactured October 1, 2019, through August 19, 2021. Alternator Power Cable Connection Securement Repair 1. Park the vehicle on a level surface, turn engine OFF, chock tires, and turn the main power disconnect switch (MPDS) to the OFF Position. The MPDS switch is located in the battery box compartment. 2. Disconnect negative battery cables at the batteries. 3. Open the engine compartment door for the HDX. See Fig. 1. For HDX vehicles, go to step 12. For EFX vehicles, continue to next step. 4. Access the engine cover for the EFX. See Fig. 2. Fig. 1, HDX Engine Compartment, Typical Fig. 2, EFX Engine Cover, Typical Daimler Trucks North America LLC Recall Campaign Page 7 Latch December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) 5. Reposition the EFX engine cover as shown in Fig. 3, Fig. 4, and Fig. 5 to gain access to the alternator power cable securement nut at the rear of the alternator. Fig. 3, Open rear access door Fig. 4, Flip latch up to unlock cover from floor 6. Tighten the alternator power cable-anchoring nut to the value shown in Fig, 7, and identified in Fig. 6 circled in yellow. 7. Connect the negative battery cable at the batteries, turn the main power disconnect switch to the ON position. 8. Start engine to check that the repair functions as intended. 9. Reverse the engine cover removal process, and latch the engine cover into place. 10. Unchock the tires, and release the EFX vehicle back into service. NOTICE TORQUE VALUE is in lbf·in Alternator Part Number Torque Value lbf·in TBB181725 90 TBB181726 90 Fig. 7, Torque value for the alternator power (B+) nut Fig. 6, With EFX engine cover repositioned, see the power cable connection circled in yellow (Right front of engine) Fig. 5, Lift cover up, and pull back just enough to gain access to alternator. Cover does not need removed Daimler Trucks North America LLC Recall Campaign December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) 11. Access the HDX alternator power cable securement nut through the rear engine door. See Fig. 8, Fig 9, and Fig. 10. Fig. 8, HDX Alternator location (yellow circle) is behind the belt guard (black). Access the power cable nut through the opening below the hose and above alternator Fig. 9, Yellow circle identifies the power cable nut on backside of alternator Fig. 10, Power cable connection shown from the rear view of alternator. Remove the red protection cap to access the power cable nut Page 8 Daimler Trucks North America LLC Recall Campaign December 2021 FL904 AB NHTSA # 21V-850 (School Bus) Transport Canada # 2021-669 (School Bus) 12. Tighten the alternator power cable-anchoring nut to the value shown in Fig, 11. Alternator Part Number Torque Value lbf·in TBB179526 53 TBB181726 90 Fig. 11, Torque value for the alternator power (B+) nut 13. Connect the negative battery cable at the batteries, and turn the main power disconnect switch to the ON position. 14. Connect the negative battery cable at the batteries, and turn the main power disconnect switch to the ON position. 15. Unchock the tires, and release the HDX vehicle back into service. Page 9
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-850 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Daimler Trucks North America, LLC Submission Date : NOV 10, 2021 NHTSA Recall No. : 21V-850 Manufacturer Recall No. : FL904 Manufacturer Information : Manufacturer Name : Daimler Trucks North America, LLC Address : 4747 N. Channel Avenue Portland OR 97217-3849 Company phone : 800-745-8000 Population : Number of potentially involved : 1,434 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Thomas Built Buses HDX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2020-2022 Thomas Built Buses EFX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Arcing due to a loose cable connection on an unfused power cable may increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Description of the Cause : There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Part 573 Safety Recall Report 21V-850 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. Involved Components : Component Name 1 : Nut Component Description : NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number : 23-13861-105 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. Description of Remedy : Description of Remedy Program : The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Part 573 Safety Recall Report 21V-850 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Date : DEC 31, 2021 – DEC 31, 2021 Planned Owner Notification Date : DEC 31, 2021 – DEC 31, 2021 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-850 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Daimler Trucks North America, LLC Submission Date : NOV 10, 2021 NHTSA Recall No. : 21V-850 Manufacturer Recall No. : FL904 Manufacturer Information : Manufacturer Name : Daimler Trucks North America, LLC Address : 4747 N. Channel Avenue Portland OR 97217-3849 Company phone : 800-745-8000 Population : Number of potentially involved : 1,434 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Thomas Built Buses EFX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2020-2022 Thomas Built Buses HDX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Arcing due to a loose cable connection on an unfused power cable may increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Description of the Cause : There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Part 573 Safety Recall Report 21V-850 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. Involved Components : Component Name 1 : Nut Component Description : NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number : 23-13861-105 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. Description of Remedy : Description of Remedy Program : The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Part 573 Safety Recall Report 21V-850 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Date : DEC 31, 2021 – DEC 31, 2021 Planned Owner Notification Date : DEC 31, 2021 – DEC 31, 2021 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-850 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Daimler Trucks North America, LLC Submission Date : FEB 11, 2022 NHTSA Recall No. : 21V-850 Manufacturer Recall No. : FL904 Manufacturer Information : Manufacturer Name : Daimler Trucks North America, LLC Address : 4747 N. Channel Avenue Portland OR 97217-3849 Company phone : 800-745-8000 Population : Number of potentially involved : 1,434 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Thomas Built Buses EFX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2020-2022 Thomas Built Buses HDX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Arcing due to a loose cable connection on an unfused power cable may increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Description of the Cause : There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Part 573 Safety Recall Report 21V-850 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. Involved Components : Component Name 1 : Nut Component Description : NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number : 23-13861-105 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. In February 2022, NHTSA asked for updated information on warranty claims, field service reports, and other things such as the number of deaths and injuries. The response is: • In July 2021, DTNA received a dealer notification, described above. Also that month, DTNA received seven claims, within the 17 cited above. • In August 2021, DTNA discovered five claims where the alternator cable was loose or detached from the power stud on the alternator, as part of the investigation described above. • In September 2021, DTNA received three additional claims, also within the 17 cited above. • Subsequent warranty searches revealed other claims, with potentially similar failure modes although Part 573 Safety Recall Report 21V-850 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 the link cannot be verified–one in December 2020 and another in March of 2021. • There were no injuries or deaths reported. Description of Remedy : Description of Remedy Program : The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Date : DEC 31, 2021 – DEC 31, 2021 Planned Owner Notification Date : DEC 31, 2021 – DEC 31, 2021 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-850 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Daimler Trucks North America, LLC Submission Date : NOV 02, 2021 NHTSA Recall No. : 21V-850 Manufacturer Recall No. : FL904 Manufacturer Information : Manufacturer Name : Daimler Trucks North America, LLC Address : 4747 N. Channel Avenue Portland OR 97217-3849 Company phone : 800-745-8000 Population : Number of potentially involved : 1,434 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2020-2022 Thomas Built Buses EFX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : ALL Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2020-2022 Thomas Built Buses HDX Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : Certain HDX model school busses manufactured 10/01/2019 and 08/19/2021. Production Dates : OCT 01, 2019 – AUG 19, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : On the affected vehicles, the nut for the power cable stud on the alternator may not have been torqued properly. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Arcing due to a loose cable connection on an unfused power cable may result in a loss of power or, in the extreme, increase the risk of a fire. To date, however, there are no reported injuries or deaths related to this issue. Description of the Cause : There are no defective components on the bus. The defect is related to the installation at Thomas Built Buses Part 573 Safety Recall Report 21V-850 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : The battery charge light on the dash instrument cluster may indicate a problem with the alternator and cable connection. Involved Components : Component Name 1 : Nut Component Description : NUT-HEX,FLG,LOCK, 5/16-18,ZN AL Component Part Number : 23-13861-105 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : At the end of July 2021, DTNA received a notification from a dealer of a bus with a loose power cable at the alternator. The dealer reported they inspected four additional units and found the nut that secures the cable to the alternator was not fully torqued. In August, DTNA began an investigation to determine the scope of the issue. At approximately the same time and thru October 2021, DTNA undertook a detailed review of warranty and field reports. Additional instances were identified that may be related to possible loose cable connections at the alternator. In total, 17 instances were identified potentially related to loose positive cable connections at the alternator. There was one occurrence, found in a warranty claim, where the dealer linked the alternator cable connection to a loose cable connection. On October 28, 2021, DTNA with an abundance of caution, decided to conduct a voluntary recall campaign on certain Thomas Built Buses Saf-T-Liner HDX and EFX school buses that may have a loose power cable connections at the alternator. There are no reported injuries or deaths related to this issue. Description of Remedy : Description of Remedy Program : The alternator power cable connection will be inspected and torqued if necessary. Repairs will be performed by Daimler Trucks North America authorized service facilities. Details of the reimbursement plan will be included in the owner’s notification letter. Part 573 Safety Recall Report 21V-850 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 How Remedy Component Differs from Recalled Component : NR Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : Customer notification will be made by first class mail using Daimler Trucks North America records to determine the customers affected. Planned Dealer Notification Date : DEC 31, 2021 – DEC 31, 2021 Planned Owner Notification Date : DEC 31, 2021 – DEC 31, 2021 * NR – Not Reported
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