2004 Blue Bird EXPRESS 4500: complaints, problems and recalls

Reported: 2004-03-26 (March 26, 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)

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)

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)

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.