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2002–2004 Thomas Conventional, 2002–2005 Thomas ER, 2002–2005 Thomas HDX and 4 other models Recall: CERTAIN 2002-2005 MY THOMAS BUILT MINOTOUR, CONVENTIONAL, MVP-ER, ER, HDX…

NHTSA campaign 05V340000 · Other · filed Jul 25, 2005 · verified Jul 30, 2026

Units reported
14K
Manufacturer
FREIGHTLINER LLC
Risk
Safety
Owner letters
Mailing began Sep 14, 2005

The defect

CERTAIN 2002-2005 MY THOMAS BUILT MINOTOUR, CONVENTIONAL, MVP-ER, ER, HDX, AND MVP-EF MODEL SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 8, 2002, AND MARCH 8, 2005, EQUIPPED WITH SPECIALTY MFG "5" SERIES STOP ARMS ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE FOLLOWING STATES: ALASKA, COLORADO, CONNECTICUT, DELAWARE, IDAHO, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, MONTANA, NEBRASKA, NEVADA, NEW HAMPSHIRE, NEW JERSEY, NEW MEXICO, NEW YORK, NORTH DAKOTA, OHIO, OREGON, PENNSYLVANIA, RHODE ISLAND, SOUTH DAKOTA, TENNESSEE, UTAH, VERMONT, VIRGINIA, WASHINGTON, WEST VIRGINIA, WISCONSIN, WYOMING, AND THE DISTRICT OF COLUMBIA. IN EXTREMELY COLD WEATHER, THE MICROSWITCHES USED INTERNALLY TO POSITION THE STOP ARM SIGN IN THE OPEN AND CLOSED POSITIONS MAY MALFUNCTION, CAUSING THE SIGN TO OPEN OR CLOSE IN AN IMPROPER POSITION, OR TO NOT OPEN AT ALL.

The risk

SHOULD THE STOP ARM NOT PERFORM PROPERLY, A CHILD OR PEDESTRIAN MAY BE ENDANGERED BY PASSING VEHICLES SHOULD THE MOTORIST NOT STOP AT THE CORRECT LOCATION.

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The fix — what to do

THOMAS BUILT WILL NOTIFY ITS OWNERS AND REPLACE THE ORIGINAL SWITCH WITH A SWITCH PACK THAT IS NOT SENSITIVE TO EXTREME COLD WEATHER AND WILL INSPECT TO ENSURE THE MICROSWITCH HEATER WIRING IS PROPERLY CONNECTED FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2005. OWNERS MAY CONTACT THOMAS BUILT'S CUSTOMER SUPPORT OFFICE AT 336-889-4871.

FREIGHTLINER/THOMAS BUILT RECALL NO. FL-454.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236; (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

Affected vehicles

Related recalls

All Thomas Conventional recalls → · All Thomas recalls →

Source: NHTSA recall database, campaign 05V340000 (manufacturer number FL-454). Data last verified Jul 30, 2026.