2004 Thomas FS-65: what breaks, and at what mileage
What breaks on the 2004 Thomas FS-65
Only 1 defect report has been filed with NHTSA about the 2004 Thomas FS-65, which is too few to compute mileage percentiles or a risk score. The report reported other electrical problem.
When each failure gets reported
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
How reports accumulate
Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A curve that climbs early is a car with early problems, whatever its total.
- Line share of reports filed by that mileage
Every reported failure mode
| Failure mode | System | Reports | With reading | 25th | Median | 75th | Per 1,000 | Typical repair | Severity |
|---|---|---|---|---|---|---|---|---|---|
| Other electrical problem | electrical | 1 | 1 | — | 42k | — | 1.3 | $250–$2,000 | Moderate |
Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound. Repair costs are typical independent-shop ranges for the failure, not figures from these reports.
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The odometer reading is the one the owner gave.
Other electrical problem
After start-up when vehicle was idling for approximately 20 minutes started smoking from underneath the dash panel. It was approximately minutes 10 later when the fire was first noticed; time line is the best we can determine from video footage. Fire department arrived 10 minutes late and the bus was consumed by flames. The bus was destroyed beyond repair. *tr
Recalls on the 2004 model year
NHTSA has issued 2 recall campaigns covering the 2004 Thomas FS-65, affecting an estimated 1,207 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.
The campaigns cover service brakes, hydraulic and tires. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.
Recalls also distort complaint counts. Publicity about a campaign reminds owners that complaining is possible, so reports for a recalled component often spike after the recall rather than before it.
SERVICE BRAKES, HYDRAULIC
1,630 vehicles 2005-09-20- Defect
- Certain freightliner custom chassis fs-65 school bus chassis and fb-65 shuttle bus chassis equipped with caterpillar c7 engines and revised cooling packages and manufactured between january 24, 2004, and june 15, 2005. The front hydraulic line may rub through on a radiator tube, possibly resulting in the loss of brake fluid to the front brakes.
- Consequence
- The defect may cause the loss of front brakes, resulting in extended stopping distances and possibly a vehicle crash.
- Remedy
- Freightliner and thomas built will notify its customers and will inspect and secure the brake line to provide more clearance free of charge. The recall began on january 20, 2006. Owners may contact freightliner at 1-800-547-0712.
TIRES
4,000 vehicles 2004-12-22- Defect
- Certain michelin xde commercial truck tires, size 10r22.5 lrg and lrf for use on freightliner school and transit buses. These tires were manfactured between may 23 and october 24, 2004, can experience rapid air loss due to an irregularity of the inner liner.
- Consequence
- Rapid air loss can result in loss of vehicle control and a vehicle crash can occur.
- Remedy
- Michelin will notify its customers and replace the tires free of charge. The recall began december 27, 2004. Owners who do not receive the free remedy within a reasonable time should contact michelin at 888-622-2306.
Recall work is free at a franchised dealer regardless of the car's age. Check the VIN at nhtsa.gov/recalls before assuming it was done.
Every year of the Thomas FS-65
Scores compare each year against other cars of the same model year, so a low number on an older car is a real result and not an artefact of age.
What the reports on file say
The complaints recorded against the 2004 Thomas FS-65 are other electrical problem (1 report, around 42k miles). With a sample this size these are anecdotes rather than a pattern, and they are shown because somebody looking at this exact car would rather see them than nothing.
Why this page is short
A model year needs about 8 reports before percentiles mean anything, and this one does not have them. Complaint volume tracks how many cars were sold and how long they have been on the road, so a thin page usually means a rare car, a new car, or a car whose owners do not file.
Where this comes from. Every figure above is computed from NHTSA owner complaints and recall records for this exact make, model and year. Complaints are voluntary and self-selected, so treat counts as a floor. The methodology page writes out each formula, and the same numbers are available as JSON.
What breaks at my mileage Compare with another car
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed