Recall 16V407 covers 717 1998-2002 Thomas Built Buses bus models for corroding emergency-door handle stems. Repair is free at any franchised Thomas Built Buses dealer.
Thomas Built Buses is recalling 717 1998-2002 buses, including Saf-T-Liner Mvp-Ef, Saf-T-Liner Er, CL-960, Vista, TL-960, Saf-T-Liner Mvp-Er, and Saf-T-Liner Conventional models, because the stem connecting the outside emergency door handle to the opening mechanism can corrode. If the handle detaches, emergency door opening and bus evacuation can be delayed, increasing injury risk; Thomas Built Buses dealers will complete the repair free of charge.
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What's wrong?
The issue is in the outside emergency door handle and the stem behind it. That stem links the handle on the outside of the bus to the latch mechanism that opens the emergency door. In normal use, pulling the handle moves the stem, and that motion releases the door so passengers and responders have an exit path.
On affected 1998-2002 Thomas Built Buses buses, the emergency door design exposes the handle stem to corrosion. As corrosion builds, the metal stem weakens. A weakened stem can break instead of moving the latch, leaving the outside handle disconnected from the door opening mechanism. DTNA traced the recall to door handle stem configurations with a high corrosion rate.
There is no warning sign before failure. The handle can look normal until the stem breaks, so an outside visual check does not confirm that the emergency door mechanism is ready to open.
Who's affected?
Spans 7 bus models across the 1998-2002 model years, all tied to the body door structure component.
| 2000 Thomas Built Buses Saf-T-Liner Mvp-Ef | body structure |
|---|---|
| 2001 Thomas Built Buses Saf-T-Liner Er | body structure |
| 2000 Thomas Built Buses CL-960 | body structure |
| 1999 Thomas Built Buses Vista | body structure |
| 1998 Thomas Built Buses Vista | body structure |
| 2001 Thomas Built Buses Saf-T-Liner Mvp-Ef | body structure |
| 2000 Thomas Built Buses TL-960 | body structure |
| 2001 Thomas Built Buses CL-960 | body structure |
| 2001 Thomas Built Buses Saf-T-Liner Mvp-Er | body structure |
| 2001 Thomas Saf-T-Liner Conventional | body structure |
| 2000 Thomas Built Buses Saf-T-Liner Mvp-Er | body structure |
| 2002 Thomas Built Buses Saf-T-Liner Mvp-Er | body structure |
| 2002 Thomas Built Buses TL-960 | body structure |
| 2002 Thomas Built Buses Saf-T-Liner Er | body structure |
| 2001 Thomas Built Buses TL-960 | body structure |
| 2002 Thomas Built Buses Saf-T-Liner Mvp-Ef | body structure |
| 1999 Thomas Saf-T-Liner Conventional | body structure |
| 1998 Thomas Saf-T-Liner Conventional | body structure |
| 2000 Thomas Saf-T-Liner Conventional | body structure |
| 2000 Thomas Built Buses Saf-T-Liner Er | body structure |
| 2002 Thomas Saf-T-Liner Conventional | body structure |
| Units affected | 717 |
| Field incidents | NHTSA has logged 1 field incident to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
When the emergency door handle stem corrodes, the handle can detach from the opening mechanism. This can delay door opening during an evacuation and increase injury risk for bus occupants. Have the recall repair completed soon so the emergency door opens as intended. Repair is free at any franchised Thomas Built Buses dealer.
What should I do?
- Check your VIN to confirm your 1998-2002 Thomas Built Buses bus is included in this recall.
- Contact a franchised Thomas Built Buses dealer to schedule the free emergency-door-handle stem repair, which replaces or protects the corroded stems so the emergency door opens during evacuation.
- Bring the recall notice if Thomas Built Buses mailed one. If not, reference recall number 16V407 when you call.
- Inspect the outside emergency door handle before trips until the repair is complete, and report any loose or corroded handle to the dealer.
- Call Thomas Built Buses customer service at 1-800-547-0712 with questions about scheduling or parts.
What happens at the repair
At the dealer, a Thomas Built Buses technician either replaces the outside emergency door handle stems or protects the stems against corrosion. The repair is available now, and parts and labor are covered under the recall. If you've already paid for a related emergency door handle repair before the recall notice, the manufacturer's standard reimbursement plan covers documented expenses. Bring receipts or repair paperwork to the service desk, or contact customer service to ask how to submit the claim.
| Reimbursement | Reimbursement available |
|---|
Timeline
| June 7, 2016 | NHTSA published the recall |
|---|---|
| July 29, 2016 | Dealer notification began |
| July 29, 2016 | Dealer notification ended |
| July 29, 2016 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| July 29, 2016 | Interim owner notification (was planned for this date) |
| December 9, 2016 | Owner notification mailed |
Frequently asked questions
What is recall 16V407?
Recall 16V407 covers 717 1998-2002 Thomas Built Buses transit buses with outside emergency door handle stems that can corrode. If the stem corrodes, the handle can detach from the emergency door opening mechanism, delaying evacuation and increasing injury risk. Dealers will replace or protect the stems for free.
What should I do if my 1998-2002 Thomas Built Buses bus is on this recall?
Check your VIN to confirm your specific bus is included in recall 16V407. If it is, contact a franchised Thomas Built Buses dealer to schedule the emergency door handle stem repair. Reference recall number 16V407 and DTNA recall number FL-713 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and DTNA says dealers will replace the stems or protect them against corrosion free of charge. Parts are available for this recall.
What is the safety risk?
The safety risk is delayed evacuation during an emergency. Recall 16V407 says corrosion can let the outside emergency door handle detach from the opening mechanism, slowing door opening and increasing injury risk for bus occupants. The repair addresses the corroded stem condition.
What if I bought this Thomas Built Buses bus used?
The free recall repair still applies. Recall eligibility follows the VIN, not the original owner. Check your VIN, then give the dealer recall number 16V407 and DTNA recall number FL-713 when scheduling the emergency door handle stem repair.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V407000 |
|---|---|
| Thomas Built Buses customer service | 1-800-547-0712 |
| NHTSA recall # | 16V407 |
| NHTSA recall # (full) | 16V407000 |
Source documents
-
Download Misc. Document (PDF) - Download Recall Document (PDF) (PDF)
- Download Recall Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →