The 1991 Thomas Built School Bus has 11 NHTSA recall campaigns affecting an estimated 140,481 vehicles. Recall repairs are always free at any authorized dealer. Last updated July 5, 2026.
THE DOOR HINGES WERE NOT SHIELDED AND CAN SNAG EXITING CHILDREN'S CLOTHING OR ACCESSORIES.
WHEN A PASSENGER'S CLOTHING BECOMES CAUGHT IN THE HANDRAIL, AND THE BUS DRIVER CLOSES THE DOOR AND PUTS THE VEHICLE IN MOTION, THE INDIVIDUAL IS SUBJECT TO BEING DRAGGED BY THE BUS. THIS CAN RESULT IN SERIOUS INJURY OR DEATH.
DEALERS WILL INSTALL HINGE PADS TO PREVENT THE SNAGGING OF PASSENGER'S CLOTHING.
PASSENGER'S CLOTHING CAN UNKNOWINGLY BECOME CAUGHT IN THE HANDRAILS AT BUS DOORS WHEN EXITING THE BUS.
WHEN A PASSENGER'S CLOTHING BECOMES CAUGHT IN THE HANDRAIL, AND THE BUS DRIVER CLOSES THE DOOR AND PUTS THE VEHICLE IN MOTION,THE INDIVIDUAL IS SUBJECT TO BEING DRAGGED BY THE BUS. THIS CAN RESULT INSERIOUS INJURY OR DEATH.
REPLACE OR REPOSITION THE HANDRAILS TO STOP CLOTHING FROM BEING CAUGHT.
A DECAL WARNING OF THE POTENTIAL DANGER IN USING STARTING FLUID TO START THE ENGINE WAS OMITTED.
IGNITION OF THE STARTER FLUID BY THE HEATING ELEMENT CAN RESULT IN AN EXPLOSION CAUSING ENGINE DAMAGE AND PERSONAL INJURY.
CUSTOMERS WILL BE SENT WARNING DECALS AND INSTALLATION INSTRUCTIONS.
PASSENGERS CLOTHING CAN UNKNOWINGLY BECOME CAUGHT IN THE HANDRAILS AT BUS DOORS WHEN EXITING THE BUS.
WHEN A PASSENGER'S CLOTHING BECOMES CAUGHT IN THEHANDRAIL, AND THE BUS DRIVER CLOSES THE DOOR AND PUTS THE VEHICLE IN MOTION, THEINDIVIDUAL IS SUBJECT TO BEING DRAGGED BY THE BUS. THIS CAN RESULT IN SERIOUSINJURY OR DEATH.
REPLACE OR REPOSITION THE HANDRAILS TO STOP CLOTHING FROM BECOMING CAUGHT.
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.
THE CURRENT PRODUCTION STATIONARY WINDOW ASSEMBLIES ALLOW THE GLASS TO DISENGAGE FROM THE RUBBER AND/OR FRAME.
THE WINDOWS DO NOT COMPLY WITH FMVSS 217, "BUS WINDOWRETENTION AND RELEASE."
INSTALL TWO RETAINING CLIPS AT EACH NON-COMPLYING WINDOW.
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 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.
SOME OF THE SPECIAL FASTENERS ATTACHING THE SEATS TO THE FLOOR TRACKS ARE OF SUBSTANDARD QUALITY AND ARE NOT CAPABLE OF HOLDING THE SEAT TO THE FLOOR.
IN THE EVENT OF A SUDDEN STOP OR ACCIDENT, SEAT OCCUPANTSWOULD BE PLACED AT INCREASED RISK OF INJURY FROM SEATS BREAKING FREE OF THEFLOOR; BUSES WOULD NOT COMPLY WITH FMVSS 222.
REPLACE SUBSTANDARD FASTENERS WITH NEW FASTENERS.
There is no summary currently available
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 School Bus as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.