Blue Bird EXPRESS 4500 recalls by model year

Reported: 2004-03-26 (March 26, 2004) · Model years: 2004

ON CERTAIN MOTOR HOMES AND TRANSIT COACHES, INCORRECT TORQUE APPLICATION COULD HAVE BEEN APPLIED TO THE CLAMP BOLTS AND THE DRAG LINK.

Consequence: THIS COULD LEAD TO THE CLAMPS BECOMING LOOSE, CAUSING MISALIGNMENT OF THE STEERING AXLES, WHICH COULD RESULT IN A LOSS OF VEHICLE CONTROL, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE CLAMP BOLTS AND AND TIGHTEN TO THE REQUIRED TORQUE. OWNER NOTIFICATION BEGAN ON APRIL 7, 2004. OWNERS SHOULD CONTACT BLUE BIRD AT 478-822-2242.

Reported: 2004-07-19 (July 19, 2004) · Model years: 2004

CERTAIN MOTOR COACHES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, "AIR BRAKE SYSTEMS." THESE BUSES WERE MANUFACTURED WITHOUT THE CHECK VALVE, WHICH PROTECTS THE FRONT SERVICE BRAKE RESERVOIR.

Consequence: LOSS OF AIR PRESSURE COULD RESULT IN LONGER STOPPING DISTANCES WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL ADD THE REQUIRED CHECK VALVE TO THE FRONT AIR BRAKE SERVICE RESERVOIR TO INSURE COMPLIANCE WITH FMVSS NO. 121. THE RECALL BEGAN ON JULY 30, 2004. OWNERS SHOULD CONTACT BLUE BIRD AT 478-822-2242.

Reported: 2004-08-04 (August 4, 2004) · Model years: 2004

CERTAIN MOTOR COACHES, MOTOR HOMES, COMMUTER COACHES, AND TRANSIT BUSES EQUIPPED WITH ARVIN-MERITOR DX 225 AIR DISC BRAKES, ARE EXPERIENCING EXCESSIVE SMOKE IN THE WHEEL AREA DUE TO OVERHEATING OF THE AIR DISC BRAKE PADS.

Consequence: A POTENTIAL FIRE IN THE WHEEL MAY OCCUR WHICH MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY.

Remedy: ARVIN-MERITOR WILL INSPECT THE BRAKE ASSEMBLIES TO ENSURE PROPER SET-UP AND OPERATION. THIS RECALL BEGAN AUGUST 10, 2004. OWNERS SHOULD CONTACT BLUE BIRD AT 478-822-2242.

Reported: 2013-10-17 (October 17, 2013) · Model years: 2004, 2005, 2006, 2007

Blue Bird Body Company (Blue Bird) is recalling certain model year 2004 Ultra LMB, 2003-2006 Ultra LF and 2004-2007 Express commercial buses equipped with Sure Power-brand battery equalizers containing a particular epoxy sealing, aka 'potting', compound. The specific potting compound used in the subject products for insulation was found to be capable of conducting electricity after being exposed to heat.

Consequence: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

Remedy: Blue Bird will notify owners, and dealers will replace the equalizers, free of charge. The recall began on December 17, 2013. Owners may contact Blue Bird at 1-478-825-2021. Blue Bird's recall number is R13WN.

Reported: 2007-11-21 (November 21, 2007) · Model years: 2006

ON CERTAIN MOTOR COACHES, THE CASTLE NUTS ON THE TIE ROD ENDS AND RELAY ROD STUDS IN THE INDEPENDENT SUSPENSION ASSEMBLIES ARE LOOSE AND/OR NOT TIGHTENED TO SPECIFICATIONS. LOW AND/OR NO TORQUE ON A NUT CAN RESULT IN EXCESSIVE SLACK IN THE STEERING SYSTEM, THEREBY ALLOWING THE TAPERED JOINT TO MOVE AND SUBSEQUENTLY SHEAR THE COTTER PIN.

Consequence: THIS CONDITION CAN RESULT IN THE STEERING LINK TO BECOME DISCONNECTED AND CAUSE A LOSS OF STEERING CONTROL WHICH COULD RESULT IN A CRASH.

Remedy: BLUE BIRD IS WORKING WITH ARVIN-MERITOR TO REPAIR THESE COACHES (PLEASE SEE 07E094). THE RECALL BEGAN ON NOVEMBER 19, 2007. OWNERS MAY CONTACT BLUE BIRD AT 1-478-822-2242.

Reported: 2008-06-10 (June 10, 2008) · Model years: 2006, 2007

BLUE BIRD IS RECALLING 33 MY 2006-2007 EXPRESS 4500 MOTOR COACHES EQUIPPED WITH MAC TIE ROD ASSEMBLIES THAT DID NOT MEET DESIGN SPECIFICATION. AS A RESULT, THE LEFT AND/OR RIGHT TIE ROD ASSEMBLY MAY FRACTURE AT HIGH MILEAGE.

Consequence: A FRACTURE TIE ROD MAY SEPARATE WITHOUT PRIOR WARNING CAUSING UNEXPECTED LOSS OF VEHICLE STEERING. IN SOME MANEUVERS THIS COULD CAUSE A CRASH.

Remedy: DEALERS WILL REPLACE THE LEFT AND RIGHT HAND TIE ROD ASSEMBLIES WITH A REDESIGNED TIE ROD ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON JULY 11, 2008. OWNERS MAY CONTACT BLUE BIRD AT 478-822-2242.