Blue Bird COMMERCIAL SERIES recalls by model year

Reported: 2000-05-05 (May 5, 2000) · Model years: 1995, 1996, 1997, 1998, 1999, 2000

VEHICLE DESCRIPTION: SCHOOL BUSES EQUIPPED WITH TRANSIT SLIDING PUSHOUT WINDOWS. POTENTIAL STICKING AND/OR BINDING OF THE PUSHOUT WINDOW INNER FRAME WITHIN THE OUTER FRAME RESULTS IN OPENING FORCES EXCEEDING THE REQUIREMENTS OF FMVSS NO. 217, "BUS WINDOW RETENTION AND RELEASE."

Consequence: PERSONAL INJURY COULD OCCUR IN THE EVENT OF A CRASH.

Remedy: OWNERS WILL BE PROVIDED WITH STEP-BY-STEP PROCEDURES FOR MODIFYING THE TRANSIT SLIDING PUSHOUT WINDOWS TO CONFORM THE FMVSS 217 REQUIREMENTS.

Reported: 2001-06-11 (June 11, 2001) · Model years: 1996, 1997, 1998, 1999, 2000, 2001

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH REAR MOUNTED ENGINES. THE 12-VOLT POWER SUPPLY CABLE(S) MAY BE CHAFFED BY HOSES, HARNESSES, FRAME COMPONENTS, OR CLAMPS.

Consequence: THIS CONDITION CAN RESULT IN POWER FAILURE AND/OR RISK OF FIRE IN THE ENGINE COMPARTMENT.

Remedy: DEALERS WILL REMOVE AND INSPECT THE 12-VOLT POWER CABLE(S) FROM THE BATTERY TO THE STARTER AND, IF NECESSARY, WILL REPLACE THE CABLES. OWNER NOTIFICATION BEGAN JULY 30, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BLUE BIRD AT 1-912-822-2242.

Reported: 2000-06-12 (June 12, 2000) · Model years: 1997, 1998, 1999

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH BENDIX AIR BRAKES. BENDIX CHANGED THE INTERNAL DESIGN OF THE QR1C RELAY VALVE BY ADDING A HOLE IN THE INTERNAL DIAPHRAGM. WHEN THE HOLE IN THE DIAPHRAGM ALIGNS WITH THE HOLE IN THE VALVE BODY, THE BRAKE APPLICATION TIME INCREASES.

Consequence: UNDER CERTAIN CONDITIONS, SUCH AS PARKED ON AN INCLINE, DRIVER ACTIVATES THE PARKING BRAKE BUT REMOVES FOOT FROM THE THREADLE VALVE, THE BUS COULD ROLL BEFORE THE PARKING BRAKE IS FULLY ENGAGED.

Remedy: DEALERS WILL REPLACE THE DIAPHRAGMS WITH HOLES WITH SOLID DIAPHRAGMS FOR THE QR1C VALVES.

Reported: 2000-02-22 (February 22, 2000) · Model years: 1998, 1999

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH BENDIX ABS ANTI-LOCK BRAKING SYSTEM. THE PRIMARY AND SECONDARY BRAKE TREADLE VALVE AIR LINES WERE INSTALLED INCORRECTLY AT THE BENDIX R12DC RELAY VALVE.

Consequence: WITH THE BRAKE SYSTEM INSTALLED INCORRECTLY, FUTURE MAINTENANCE MIGHT BE AFFECTED BY THIS INCONSISTENCY, CAUSING THE BRAKES TO BE INSTALLED INCORRECT, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL CORRECT THE AIR LINE PLUMBING AT THE BENDIX R12DC RELAY VALVE.

Reported: 2002-09-05 (September 5, 2002) · Model years: 1998

ON CERTAIN FRONT ENGINE SCHOOL AND TRANSIT BUSES EQUIPPED WITH BLUE BIRD OPTION 40177 CUMMINS ISB ENGINE, THE ALTERNATOR POWER CABLES MAY NOT BE ROUTED PROPERLY FROM THE ALTERNATOR OUTPUT TO THE STARTER MOTOR.

Consequence: IF THE CABLES ARE NOT ROUTED PROPERLY, THE CABLE INSULATION COULD BE ABRADED BY CONTACT WITH OTHER CHASSIS COMPONENTS RESULTING IN A SHORT TO GROUND.

Remedy: DEALERS WILL ADD A LOOM AND REROUTE THE ELECTRICAL POWER CABLE FROM ALTERNATOR OUTPUT TO STARTING MOTOR. THE ALTERNATOR POWER CABLE WILL BE REPLACED IF ABRASIONS ARE FOUND. OWNER NOTIFICATION IS EXPECTED TO BEGIN ON OR ABOUT SEPTEMBER 30, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BLUE BIRD AT 1-478-822-2242.

Reported: 2003-03-28 (March 28, 2003) · Model years: 1998, 1999

ON CERTAIN SCHOOL AND TRANSIT BUSES EQUIPPED WITH CUMMINS ISB 6 CYLINDER ENGINES, THE LOWER ALTERNATOR SUPPORT BRACE OR MOUNTING HARDWARE CAN LOOSEN OR BREAK WHICH WILL ALLOW THE ALTERNATOR TO DROP ONTO THE ENGINE.

Consequence: IN THIS EVENT, THE ELECTRICAL WIRING HARNESS MAY BE DAMAGED AND THE POSSIBILITY OF FIRE MAY EXIST.

Remedy: CUMMINS WILL NOTIFY CUSTOMERS AND REPLACE THE UPPER AND LOWER ALTERNATOR SUPPORT BRACKETS FREE OF CHARGE. OWNERS WHO TAKE THEIR VEHICLE TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CUMMINS AT 1-800-343-7357 OR BLUE BIRD AT 478-822-2242.

Reported: 2005-02-22 (February 22, 2005) · Model years: 1998, 1999, 2000, 2001, 2002

CERTAIN 1998 THROUGH 2002 BLUE BIRD ALL AMERICAN, TC2000 SCHOOL AND TRANSIT BUSES, AND COMMERCIAL SERIES BUSES EQUIPPED WITH CUMMINS ISB DIESEL ENGINES. THE FUEL PUMP COULD FAIL TO TRANSFER FUEL APPROPRIATELY CREATING AN ENGINE STALL CONDITION.

Consequence: SHOULD THE ENGINE STALL WHILE THE VEHICLE IS IN USE, A POSSIBLE VEHICLE CRASH COULD OCCUR.

Remedy: CUSTOMERS WILL BE NOTIFIED BY CUMMINS TO BRING THEIR VEHICLES TO AN AUTHORIZED DEALER TO HAVE THE FUEL LIFT PUMP REPLACED FREE OF CHARGE. FOR MORE INFORMATION, CUSTOMERS MAY CONTACT CUMMINS AT 1-800-DIESELS.

Reported: 2000-08-17 (August 17, 2000) · Model years: 1999, 2000

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH ELECTRONIC ENGINES AND FELSTED ELECTRONIC ACCELERATOR PEDALS. THE RETURN SPRINGS CAN BREAK ON THE ACCELERATOR PEDALS THAT ARE EQUIPPED WITH STAINLESS STEEL OR ELECTROPLATED MUSIC WIRE RETURN SPRINGS.

Consequence: THIS CONDITION COULD CAUSE THE PEDAL TO GO TO FULL THROTTLE IF BOTH RETURN SPRINGS BREAK, INCREASING THE RISK OF A CRASH.

Remedy: REPLACEMENT ACCELERATOR PEDALS EQUIPPED WITH RETURN SPRINGS MANUFACTURED OF MUSIC WIRE WITH ONE ADDITIONAL COIL ON EACH SPRING AND WITH AN ORGANIC COATING, ELIMINATING ELECTROPLATING WILL BE INSTALLED.

Reported: 2000-12-18 (December 18, 2000) · Model years: 1999, 2000, 2001

VEHICLE DESCRIPTION: TRANSIT AND SCHOOL BUSES EQUIPPED WITH MERITOR WABCO PHASE 1, D-VERSION ANTILOCK BRAKE SYSTEM (ABS), FAIL TO COMPLY TO THE REQUIREMENTS OF FMVSS NO. 105, "HYDRAULIC AND ELECTRIC BRAKE SYSTEMS." AN INTERNAL DIAGNOSTIC SYSTEM IN THE ABS MAY NOT DETECT AN EXTREME WHEEL SPEED SENSOR AIR GAP. SUCH A CONDITION COULD POSSIBLY OCCUR DURING (1) ORIGINAL ASSEMBLY OR (2) SUBSEQUENT WHEEL END SERVICE.

Consequence: FAILURE OF THE ELECTRONIC CONTROL UNIT TO DETECT AN EXTREME WHEEL SPEED SENSOR AIR GAP CAN RESULT IN THE LOSS OF ANTILOCK BRAKING FUNCTION ON THE WHEEL(S) WHERE THE AIR GAP EXISTS, INCREASING THE RISK OF A CRASH.

Remedy: THE ABS ECU WILL BE REMOVED AND REPLACED OR THE ECU WILL BE REPROGRAMMED.

Reported: 2001-02-23 (February 23, 2001) · Model years: 1999

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES AND MOTOR HOME CHASSIS EQUIPPED WITH TIE ROD ASSEMBLIES MANUFACTURED BY TRW. THE SUSPECT TIE RODS CONTAIN 24-DL MODEL BALL SOCKETS. CERTAIN OF THE TIE ROD BALL-SOCKET BEARINGS HAVE A BELOW-SPECIFICATION CASE DEPTH AND/OR HARDNESS, WHICH CAN LEAD TO PREMATURE WEAR OF THE SOCKET.

Consequence: IF THIS CONDITION OCCURS, THE DRIVER CAN LOSE PARTIAL CONTROL OF THE RIGHT FRONT WHEEL, POSSIBLY RESULTING IN A CRASH.

Remedy: DEALERS WILL REPLACE THE DEFECTIVE BALL SOCKETS AND/OR DRAG LINKS. OWNER NOTIFICATION BEGAN MARCH 30, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BLUE BIRD AT 1-912-822-2242 OR TRW CUSTOMER SERVICE AT 1-866-280-3287.

Reported: 2001-11-02 (November 2, 2001) · Model years: 1999, 2000, 2001

VEHICLE DESCRIPTION: SCHOOL BUSES EQUIPPED WITH HENDRICKSON REAR AIR SUSPENSION. INADEQUATE TIGHTENING OF THE 5/8" BOLTS ON THE REAR AIR SUSPENSION HANGER BOLTS AND ON REAR AXLE TORQUE ARM AXLE SEAT STUDS.

Consequence: INSUFFICIENT TIGHTENING PERMITS MOVEMENT BETWEEN THE COMPONENTS THAT COULD RESULT IN BOLTS AND STUDS BREAKING, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE 5/8" GRADE 8-HANGER BOLTS. IN ADDITION, AXLE SPRING SEAT FASTENERS WILL BE CHECKED FOR PROPER TIGHTNESS AND, IF NEEDED, TIGHTENED TO SPECIFICATIONS. OWNER NOTIFICATION BEGAN JANUARY 18, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BLUE BIRD AT 1-478-822-2242.

Reported: 2004-08-30 (August 30, 2004) · Model years: 1999, 2000, 2001, 2002, 2003, 2004

CERTAIN BLUE BIRD 1999-2005 ALL AMERICAN, TC/2000, MICRO BIRD, VISION, CONVENTIONAL, AND COMMERCIAL SERIES SCHOOL BUSES EQUIPPED WITH SURE-LOC WHEELCHAIR SECUREMENT SYSTEMS AND MANUFACTURED BETWEEN FEBRUARY 17, 1999, AND AUGUST 13, 2004. CERTAIN SURE-LOK WHEELCHAIR TIE-DOWN SECUREMENT ASSEMBLIES P/N 8625-13. THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY MAY BE OUT OF ALIGNMENT CAUSING THE LOAD PAWL NOT TO FULLY SEAT IN THE SPROCKET TEETH.

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES.

Remedy: BLUE BIRD WILL NOTIFY ITS CUSTOMERS AND REPLACE THE DEFECTIVE PART FREE OF CHARGE. THE RECALL BEGAN SEPTEMBER 21, 2004. OWNERS WHO TAKE THEIR BUSES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT AT BLUE BIRD AT 478-822-2242.

Reported: 2005-04-07 (April 7, 2005) · Model years: 2001, 2002, 2003, 2004

CERTAIN 2001 THROUGH 2005 ALL AMERICAN, COMMERCIAL SERIES, AND Q-BUS SCHOOL AND TRANSIT BUSES EQUIPPED WITH JOHN DEERE 8.1 CNG ENGINES. THE SUBJECT BUSES EQUIPPED WITH THE JOHN DEERE ENGINES MAY SURGE INAPPROPRIATELY DUE TO ERRACTIC OPERATION OF THE AIR THROTTLE IF THE ENGINE IS TAKEN FROM FULL TO ZERO LOAD.

Consequence: UNEXPECTED ENGINE SURGE COULD RESULT IN A VEHICLE CRASH, POSSIBLY RESULTING IN PERSONAL INJURY.

Remedy: JOHN DEERE WILL NOTIFY BLUE BIRD'S CUSTOMERS AND REPAIR THE ENGINES FREE OF CHARGE. CUSTOMERS ARE BEING INSTRUCTED TO CONTACT JOHN DEERE AT 1-800-JD-ENGINE.

Reported: 2002-07-09 (July 9, 2002) · Model years: 2002

ON CERTAIN SCHOOL AND TRANSIT BUSES EQUIPPED WITH ALLISON 2000 SERIES TRANSMISSIONS, THE "RANGE INHIBITED" INDICATOR LIGHT ON THE DASH WAS IMPROPERLY INSTALLED AND DOES NOT FUNCTION.

Consequence: THE OPERATOR WILL NOT BE ALERTED THAT THE TRANSMISSION OPERATION IS BEING INHIBITED AND THAT THE RANGE SHIFTS BEING REQUESTED BY THE OPERATOR MAY NOT OCCUR, INCREASING THE RISK OF A CRASH.

Remedy: DISTRIBUTORS AND OWNERS WILL BE INSTRUCTED TO REMOVE THE DASH AND ACTIVATE THE INDICATOR "RANGE INHIBITED" LIGHT ACCORDING TO INSTRUCTIONS PROVIDED. OWNER NOTIFICATION BEGAN AUGUST 16, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BLUE BIRD AT 1-478-822-2242.

Reported: 2002-08-12 (August 12, 2002) · Model years: 2002, 2003

ON CERTAIN REAR ENGINE SCHOOL AND TRANSIT BUSES EQUIPPED WITH CUMMINS ISB ENGINES, THE WIRING HARNESS TO THE COMBUSTION AIR INTAKE GRID HEATER COULD CHAFE AGAINST ENGINE COMPONENTS.

Consequence: THE HARNESS CAN WEAR THROUGH CAUSING AN ELECTRICAL SHORT IN THE GRID HEATER POWER SUPPLY, INCREASING THE RISK OF A FIRE.

Remedy: OWNERS WILL BE CONTACTED AND ADVISED TO ADD A BRACKET TO SUPPORT THE HARNESS AWAY FROM THE ENGINE COMPONENTS. BLUE BIRD WILL PROVIDE A REPLACEMENT HARNESS FOR ANY HARNESSES FOUND ABRADED AND WILL REIMBURSE THE CUSTOMER FOR THE LABOR REQUIRED TO REPLACE THE HARNESS. OWNER NOTIFICATION IS EXPECTED TO BEGIN ON OR ABOUT SEPTEMBER 29, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BLUE BIRD AT 1-478-822-2242.

Reported: 2005-03-01 (March 1, 2005) · Model years: 2004

CERTAIN 2002-2006 MY BLUE BIRD ALL AMERICAN SCHOOL AND TRANSIT BUSES, CONVENTIONAL SCHOOL BUSES, AND COMMERCIAL SERIES TRANSIT BUSES MANUFACTURED BETWEEN DECEMBER 21, 2002, AND FEBRUARY 24, 2005. THESE BUSES ARE EQUIPPED WITH WEBASTO COOLANT HEATERS, MODEL DBW 2010, ASSEMBLED WITH WEBASTO BURNER TUBES, P/N 303046/26533A MANUFACTURED BETWEEN NOVEMBER 2002 AND FEBRUARY 2005. THE STAINLESS STEEL BURNER TUBE IS MADE OUT OF A MATERIAL THAT IS NOT TO SPECIFICATION AND COULD FAIL PREMATURELY.

Consequence: SHOULD THE BURNER TUBE FAIL, THE COOLANT HEATER COULD OVERHEAT, POSSIBLY RESULTING IN A FIRE.

Remedy: BLUE BIRD WILL NOTIFY ITS CUSTOMERS AND REPLACE THE BURNER TUBES FREE OF CHARGE. THE RECALL BEGAN ON MARCH 31, 2005. OWNERS MAY CONTACT BLUE BIRD AT 478-822-2242.