Recall 25V694 affects 2 2026 Thomas Built Buses Saf-T-Liner HDX2 school buses for weak rear body joints. The dealer repair is free.
Thomas Built Buses is recalling 2 2026 Saf-T-Liner HDX2 school buses because rear exterior body joints were manufactured with insufficient strength, leaving the buses out of compliance with school bus body joint requirements. Insufficient joint strength reduces passenger protection in a crash and increases injury risk; Thomas Built Buses dealers will complete the free repair.
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What's wrong?
The exterior lap joints on the 2026 Thomas Built Buses Saf-T-Liner HDX2 are the overlapping body panel joints at the rear of the school bus and near the driver's compartment. These joints help tie exterior panels together so the bus body meets the school bus body joint strength requirements in Federal Motor Vehicle Safety Standard 221.
On affected buses, adhesive was not applied according to the manufacturing instructions at certain exterior joints. Without the required adhesive bond, those joints do not have confirmed tensile strength, which means Thomas Built Buses cannot confirm that the body panels meet the required strength standard. The repair adds mechanical fasteners to the affected joints, giving the panels added attachment at the locations in question.
There is no warning sign before failure. An owner or fleet operator would not be expected to see a dashboard light, noise, or drivability change from this body joint issue.
Who's affected?
The body-structure scope centers on exterior lap joints, the manufacturer-listed part for this recall.
| 2026 Thomas Built Buses Saf-T-Liner HDX2 | body structure |
|---|---|
| Units affected | 2 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific bus is included in this recall.
What's the safety risk?
Insufficient joint strength can leave passengers with less protection in a crash and increases the risk of injury. If the VIN is included, confirm the added fasteners were installed before regular passenger service. Repair is free at any franchised Thomas Built Buses dealer.
What should I do?
- Check your VIN to confirm your 2026 Thomas Built Buses Saf-T-Liner HDX2 is included in this recall.
- Contact a franchised Thomas Built Buses dealer to schedule the free fastener repair that secures the rear exterior body joints.
- Bring the recall notice if you have one. If not, reference recall number 25V694 when you call.
- Confirm the additional fasteners are installed before returning the bus to regular passenger service.
- Call Thomas Built Buses customer service at 1-800-574-0712 with questions and reference recall number 25V694.
What happens at the repair
At the dealer, a Thomas Built Buses technician adds additional fasteners to secure the rear exterior body joints and restore joint strength. Parts and labor are covered under recall 25V694. The recall filing states all vehicles have been remedied, so the service desk can confirm whether your bus already received the fasteners. DTNA used its general reimbursement plan on file for this campaign. If you already paid for a related joint repair before the recall work, ask Thomas Built Buses service or DTNA customer service how to submit documentation under that plan.
| Reimbursement | Reimbursement available |
|---|
Timeline
| October 10, 2025 | NHTSA published the recall |
|---|---|
| October 30, 2025 | Dealer notification began |
| October 30, 2025 | Dealer notification ended |
| December 9, 2025 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 25V694?
Recall 25V694 covers 2 2026 Thomas Built Buses Saf-T-Liner HDX2 school buses with rear exterior joints that were manufactured with insufficient joint strength. The issue violates school bus body joint strength requirements, and dealers add fasteners to secure the joints for free.
What should I do if my 2026 Thomas Built Buses Saf-T-Liner HDX2 is on this recall?
Check your VIN to confirm your specific school bus is included in recall 25V694. If it is, contact a franchised Thomas Built Buses dealer and ask them to confirm the fastener repair is complete. Reference DTNA recall number F1026 when you call.
Does the recall repair cost anything?
No. Federal recall law requires manufacturers to repair safety defects at no cost to the owner. For recall 25V694, dealers add additional fasteners to secure the affected rear exterior joints free of charge.
What is the safety risk?
The safety risk is reduced passenger protection in a crash. NHTSA campaign 25V694 says a school bus with insufficient joint strength does not adequately protect passengers during a crash, increasing the risk of injury. Confirm the VIN and repair record before route service.
Have the affected school buses already been fixed?
DTNA reports that all vehicles affected by recall 25V694 have been remedied. Still, check your VIN and ask the dealer to verify completion in the service record, especially if the bus changed owners or was transferred between fleets.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V694000 |
|---|---|
| Thomas Built Buses customer service | 1-800-574-0712 |
| NHTSA recall # | 25V694 |
| NHTSA recall # (full) | 25V694000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Document (PDF) (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 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →