Recall 25V604 covers 99 2025-2026 Thomas Built Buses vehicles for improperly installed tie rod hardware. Repair is free at any franchised Thomas Built Buses dealer.
Thomas Built Buses is recalling 99 2025-2026 Saf-T-Liner C2, Saf-T-Liner C2 Jouley, Saf-T-Liner Efx, Saf-T-Liner Hdx, and Saf-T-Liner HDX2 school buses because an improperly installed tie rod castle nut and cotter pin can lead to loss of steering control. The crash risk is tied to steering control, and Thomas Built Buses dealers will complete the repair free of charge.
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What's wrong?
The tie rod assembly on affected 2025-2026 Thomas Built Buses Saf-T-Liner school buses is part of the steering linkage. It helps transfer the driver's steering input to the front wheels, so the wheels turn together and hold alignment while the bus moves.
On affected buses, the tie rod ball joint was reworked, but Thomas Built Buses and Detroit Diesel did not have records showing the castle nut was tightened to the required torque. The cotter pin, a small locking pin that helps keep the castle nut from backing off, also was not confirmed to be installed correctly. If the nut backs off, the tie rod can separate from the front axle, resulting in a loss of steering control.
A driver can notice extra free play in the steering wheel or feel that the steering alignment is off. Those are warning signs that the steering linkage is not holding the front wheels as it should.
Who's affected?
Covers five Saf-T-Liner bus models from the 2025 and 2026 model years, all tied to tie rod or steering-fastener components.
| 2026 Thomas Built Buses Saf-T-Liner C2 | tie rod (steering linkage) |
|---|---|
| 2025 Thomas Built Buses Saf-T-Liner C2 | steering system |
| 2026 Thomas Built Buses Saf-T-Liner C2 Jouley | steering system |
| 2026 Thomas Built Buses Saf-T-Liner C2 Jouley | tie rod (steering linkage) |
| 2026 Thomas Built Buses Saf-T-Liner C2 | steering system |
| 2025 Thomas Built Buses Saf-T-Liner C2 | tie rod (steering linkage) |
| 2026 Thomas Built Buses Saf-T-Liner Efx | steering system |
| 2025 Thomas Built Buses Saf-T-Liner Hdx | steering system |
| 2025 Thomas Built Buses Saf-T-Liner Hdx | tie rod (steering linkage) |
| 2026 Thomas Built Buses Saf-T-Liner Efx | tie rod (steering linkage) |
| 2026 Thomas Built Buses Saf-T-Liner HDX2 | steering system |
| 2026 Thomas Built Buses Saf-T-Liner HDX2 | tie rod (steering linkage) |
| Units affected | 99 |
| Field incidents | NHTSA has logged no field incidents 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?
A loss of steering control increases the risk of a crash. If the steering has extra free play or the alignment feels wrong, stop using the bus and contact a Thomas Built Buses dealer for inspection. Repair is free at any franchised Thomas Built Buses dealer.
What should I do?
- Check your VIN to confirm your 2025-2026 Thomas Built Buses Saf-T-Liner C2, Saf-T-Liner C2 Jouley, Saf-T-Liner Efx, Saf-T-Liner Hdx, or Saf-T-Liner HDX2 school bus is included in this recall.
- Contact a franchised Thomas Built Buses dealer to schedule the free tie-rod assembly inspection and any needed replacement that corrects the improperly installed castle nut and cotter pin.
- Reference recall number 25V604 and Thomas Built Buses recall D25R2 when you call the dealer or DTNA customer service.
- Bring the owner letter if it is available, and ask the dealer to confirm that parts and labor are covered.
- Use another bus for student transport until the steering hardware is inspected and repaired.
What happens at the repair
At the dealer, a Thomas Built Buses technician inspects the tie rod assembly, including the castle nut and cotter pin installation, and replaces the tie rod assembly if the inspection finds it is needed. The recall repair is available now, and parts and labor are covered. If you already paid for a related tie rod repair, Thomas Built Buses uses the manufacturer's general reimbursement plan on file. Bring repair paperwork and payment documentation to the service desk, or contact DTNA customer service for claim instructions.
| Reimbursement | Reimbursement available |
|---|
Timeline
| September 11, 2025 | NHTSA published the recall |
|---|---|
| October 1, 2025 | Dealer notification began |
| October 1, 2025 | Dealer notification ended |
| November 10, 2025 | Owner notification mailed |
| November 10, 2025 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 25V604?
Recall 25V604 covers 99 2025-2026 Thomas Built Buses school buses with a tie rod castle nut and cotter pin that were not installed properly. The defect can lead to loss of steering control. Dealers will inspect and replace the tie rod assembly, as needed, for free.
What should I do if my 2025-2026 Thomas Built Buses Saf-T-Liner is on this recall?
Check your VIN to confirm whether your specific bus is included in recall 25V604. If it is, contact a franchised Thomas Built Buses dealer to schedule the tie rod assembly inspection. Reference recall number 25V604 and DTNA recall number D25R2 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the safety defect at no cost. For recall 25V604, Thomas Built Buses dealers will inspect the tie rod assembly and replace it, as needed, free of charge.
What is the safety risk in recall 25V604?
The safety risk is loss of steering control. The tie rod castle nut and cotter pin were not installed properly, and that can affect the steering linkage. A loss of steering control increases the risk of a crash, so confirm the VIN and arrange the free dealer repair.
When were owners notified about recall 25V604?
Owner notification letters were mailed November 10, 2025. If your school bus changed ownership, or the notice went to a fleet office, check the VIN and call a franchised Thomas Built Buses dealer. DTNA customer service is also available at 1-800-547-0712.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V604000 |
|---|---|
| Thomas Built Buses customer service | 1-800-547-0712 |
| NHTSA recall # | 25V604 |
| NHTSA recall # (full) | 25V604000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →