Recall 10V394 covers 14 2004-2010 Thomas Built Buses Minotour buses for power cable short circuits. Free repair at a franchised Thomas Built Buses dealer.
Thomas Built Buses is recalling 14 2004-2010 Minotour non-school buses built on Ford chassis because main body power cables were routed near an unprotected passenger-side inner-fender edge. If insulation wears through, the short circuit can lead to a vehicle fire and injury, and the dealer repair will be free once available.
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What's wrong?
The main body power cables on 2004-2010 Thomas Built Buses Minotour non school buses carry electrical power through the body of the bus. These cables are insulated so the electrical current stays inside the cable and away from the metal body structure. The routing has to keep the cable clear of sharp edges, moving parts, and pinch points.
On affected Minotour buses, the cables were routed near an unprotected sharp edge on the passenger side inner fender. Under certain conditions, the cable contacts that edge. Continued contact wears through the insulation. Once the metal conductor is exposed, the cable can short circuit against the vehicle body.
There is no warning sign before failure. This is a routing and insulation problem that is found by inspection, so an owner or technician should look for cable contact, chafing, or worn insulation in that inner-fender area.
Who's affected?
Spans seven Minotour model years, all tied to the battery cables.
| 2009 Thomas Built Buses Minotour | battery |
|---|---|
| 2006 Thomas Built Buses Minotour | battery |
| 2008 Thomas Built Buses Minotour | battery |
| 2007 Thomas Built Buses Minotour | battery |
| 2010 Thomas Built Buses Minotour | battery |
| 2005 Thomas Built Buses Minotour | battery |
| 2004 Thomas Built Buses Minotour | battery |
| Units affected | 14 |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific bus.
What's the safety risk?
A short circuit in the power cable can start a vehicle fire and injure occupants. If your VIN is included, arrange the recall inspection and cable rerouting or replacement promptly. Repair will be free at any franchised Thomas Built Buses dealer once available.
What should I do?
- Check your VIN to confirm your 2004-2010 Thomas Built Buses Minotour is included in this recall.
- Contact a franchised Thomas Built Buses dealer to schedule the free power-cable inspection and rerouting or replacement that keeps the cable away from the sharp passenger-side inner-fender edge.
- Bring the recall notice if you have it. If not, reference recall number 10V394 when you call.
- Watch for signs of electrical trouble, smoke, or heat near the passenger-side inner-fender area, and stop using the bus if they appear.
- Call Thomas Built Buses customer service at 1-800-547-0712 with repair questions.
What happens at the repair
The campaign describes a dealer inspection of the main body power cables. Once the recall repair is available, a Thomas Built Buses technician inspects the cable routing near the passenger side inner fender, moves any cable away from the sharp edge, and replaces cable with damaged insulation as needed. Parts and labor are covered under the recall. The provided source does not state a separate reimbursement plan, so this section does not add a reimbursement step.
Timeline
| September 2, 2010 | NHTSA published the recall |
|---|---|
| November 18, 2010 | Owner notification mailed |
Frequently asked questions
What is recall 10V394?
Recall 10V394 covers 14 2004-2010 Thomas Built Buses Minotour non-school buses with main body power cables routed near an unprotected inner-fender edge. Contact with that edge can wear through cable insulation, causing a short circuit. Thomas Built Buses will inspect, reroute, or replace the cable for free.
What should I do if my 2004-2010 Thomas Built Buses Minotour is on this recall?
Check your VIN to confirm your specific bus is included in recall 10V394. If it is, contact a franchised Thomas Built Buses dealer or call 1-800-547-0712 to arrange the inspection and cable routing repair. Reference recall number 10V394 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to correct the defect at no cost. For recall 10V394, Thomas Built Buses will inspect the main body power cables and reroute or replace them as needed free of charge.
What is the safety risk?
The safety risk is fire and injury to people in the bus. A power cable routed against a sharp inner-fender edge can lose insulation and short circuit. If your VIN is included, schedule the free dealer inspection and repair before keeping the bus in regular service.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/10V394000 |
|---|---|
| Thomas Built Buses customer service | 1-800-547-0712 |
| NHTSA recall # | 10V394 |
| NHTSA recall # (full) | 10V394000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Defect / Noncompliance Notice (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on June 3, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →