Blue Bird Body Company: Safety Recalls in 2010

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 AND 2011 MODEL VISION SCHOOL BUSES MANUFACTURED FROM NOVEMBER 13, 2009, THROUGH DECEMBER 15, 2010. ON SOME BUSES, THE HYDRAULIC BRAKE PEDAL MAY DEFORM UPON APPLICATION WHICH MAY PREVENT THE PARKING BRAKE FROM FULLY APPLYING.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2011 ALL AMERICAN D3 MODEL SCHOOL BUSES MANUFACTURED WITH 20 GAUGE OUTSIDE SIDE PANELS FROM APRIL 23, 2010, THROUGH SEPTEMBER 11, 2010. THE SIDE PANEL JOINT ADHESIVE THAT IS REQUIRED TO BE USED TO ADHERE THE PANELS MAY NOT HAVE BEEN USED DURING PRODUCTION. ACCORDINGLY, THESE BUSES FAIL TO COMPLY WITH THE JOINT STRENGTH REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 221, "SCHOOL BUS BODY JOINT STRENGTH."

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2007 THROUGH 2010 ALL AMERICAN NON SCHOOL BUSES MANUFACTURED FROM JULY 16, 2006 THROUGH AUGUST 3, 2010 EQUIPPED WITH CUMMINS ISB-02, ISB-07, AND ISB-10 ENGINES. AN INCORRECT COMBINATION OF FLAT WASHER AND SERRATED NUT WAS INSTALLED ON THE BOLT THAT SECURES THE STARTER CABLE RETAINING CLAMP TO ITS ATTACHING BRACKET AT THE FRONT OF THE ENGINE ABOVE THE ENGINE COOLING FAN. THE FLAT WASHER PREVENTS THE SERRATED NUT FROM LOCKING AGAINST THE ATTACHING BRACKET. OVER TIME, THE SERRATED NUT MAY BACK OFF ALLOWING THE STARTER CABLE TO FALL AND CONTACT THE FAN HUB WHILE IN OPERATION.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2007 THROUGH 2010 ALL AMERICAN SCHOOL BUSES MANUFACTURED FROM MAY 29, 2006 THROUGH AUGUST 7, 2010 EQUIPPED WITH CUMMINS ISB-02, ISB-07, AND ISB-10 ENGINES. AN INCORRECT COMBINATION OF FLAT WASHER AND SERRATED NUT WAS INSTALLED ON THE BOLT THAT SECURES THE STARTER CABLE RETAINING CLAMP TO ITS ATTACHING BRACKET AT THE FRONT OF THE ENGINE ABOVE THE ENGINE COOLING FAN. THE FLAT WASHER PREVENTS THE SERRATED NUT FROM LOCKING AGAINST THE ATTACHING BRACKET. OVER TIME, THE SERRATED NUT MAY BACK OFF ALLOWING THE STARTER CABLE TO FALL AND CONTACT THE FAN HUB WHILE IN OPERATION.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 AND 2011 D3 ALL AMERICAN NON SCHOOL BUSES MANUFACTURED FROM MAY 19, 2009 THROUGH JUNE 15, 2010 AND 2011 MODEL YEAR VISION NON SCHOOL BUSES MANUFACTURED FROM APRIL 9, 2009 THROUGH APRIL 10, 2010. THESE BUSES ARE EQUIPPED WITH A CRUISE CONTROL FEATURE WHICH ONCE ACTIVATED MAY NOT DE-ACTIVATE WHEN THE SERVICE BRAKES ARE APPLIED.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 AND 2011 D3 ALL AMERICAN SCHOOL BUSES MANUFACTURED FROM MAY 13, 2009 THROUGH JUNE 25, 2010 AND 2011 MODEL YEAR VISION SCHOOL BUSES MANUFACTURED FROM NOVEMBER 9, 2009 THROUGH JUNE 24, 2010. THESE BUSES ARE EQUIPPED WITH A CRUISE CONTROL FEATURE WHICH ONCE ACTIVATED MAY NOT DE-ACTIVATE WHEN THE SERVICE BRAKES ARE APPLIED.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 ALL AMERICAN NON SCHOOL BUSES MANUFACTURED FROM MAY 19, 2009 THROUGH JULY 17, 2009 EQUIPPED WITH TRW IGEN3 INTERMEDIATE STEERING COLUMNS. THE WELD AROUND THE IGEN3 STEERING SHAFT TUBE THAT SECURES THE SPLINE TUBE TO THE INTERMEDIATE TUBE MAY BE MISLOCATED (I.E., NOT FULLY OVER THE SEAM CREATED WHEN THE TUBES ARE PRESSED TOGETHER.)

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 AND 2011 ALL AMERICAN MODEL NON SCHOOL BUSES MANUFACTURED FROM MARCH 25, 2009 THROUGH JANUARY 12, 2010. THE DRIVER'S SEAT SHOCK DAMPER MAY BREAK ALLOWING THE DRIVER'S SEAT TO UNEXPECTEDLY DROP TO THE FLOOR WITHOUT WARNING.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 AND 2011 ALL AMERICAN AND VISION MODEL SCHOOL BUSES MANUFACTURED FROM MARCH 25, 2009 THROUGH JANUARY 12, 2010. THE DRIVER'S SEAT SHOCK DAMPER MAY BREAK ALLOWING THE DRIVER'S SEAT TO UNEXPECTEDLY DROP TO THE FLOOR WITHOUT WARNING.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2010 ALL AMERICAN SCHOOL BUSES MANUFACTURED FROM MAY 13, 2009 THROUGH AUGUST 4, 2009 EQUIPPED WITH TRW IGEN3 INTERMEDIATE STEERING COLUMNS. THE WELD AROUND THE IGEN3 STEERING SHAFT TUBE THAT SECURES THE SPLINE TUBE TO THE INTERMEDIATE TUBE MAY BE MISLOCATED (I.E., NOT FULLY OVER THE SEAM CREATED WHEN THE TUBES ARE PRESSED TOGETHER.)

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2008 THROUGH 2010 ALL AMERICAN AND VISION MODEL SCHOOL BUSES MANUFACTURED FROM MAY 23, 2007 THROUGH MARCH 9, 2010, EQUIPPED WITH CATERPILLAR C7 ENGINES. THE #5 AND #6 FUEL LINES MAY CRACK AT THE FASTENING POINT TO THE COMMON FUEL RAIL AND CAUSE A FUEL LEAK.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2008 THROUGH 2010 ALL AMERICAN, VISION, AND EXCEL 102 MODEL NON SCHOOL BUSES MANUFACTURED FROM MAY 17, 2007 THROUGH NOVEMBER 13, 2008, EQUIPPED WITH CATERPILLAR C7 ENGINES. THE #5 AND #6 FUEL LINES MAY CRACK AT THE FASTENING POINT TO THE COMMON FUEL RAIL AND CAUSE A FUEL LEAK.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2004 THROUGH 2009 VISION SCHOOL BUSES MANUFACTURED FROM JANUARY 30, 2003 THROUGH SEPTEMBER 24, 2008. THE POWER CABLES RUNNING TO THE POWER DISTRIBUTION UNIT STUD AND DRIVER'S CONTROL MODULE STUD MAY HAVE BEEN INSTALLED WITH THE LUG (EYELET) FLAT SIDE UP. WHEN THIS CONDITION EXISTS, VIBRATION MAY WEAR THE INSULATION PERMITTING DIRECT CONTACT BETWEEN THE BARE LUG AND THE PDU OR DCM WHICH COULD CAUSE A DIRECT SHORT IN THE ELECTRICAL SYSTEM.

BLUE BIRD IS RECALLING CERTAIN MODEL YEAR 2004 THROUGH 2009 VISION NON-SCHOOL BUSES MANUFACTURED FROM SEPTEMBER 19, 2003 THROUGH JULY 2, 2008. THE POWER CABLES RUNNING TO THE POWER DISTRIBUTION UNIT STUD AND DRIVER'S CONTROL MODULE STUD MAY HAVE BEEN INSTALLED WITH THE LUG (EYELET) FLAT SIDE UP. WHEN THIS CONDITION EXISTS, VIBRATION MAY WEAR THE INSULATION PERMITTING DIRECT CONTACT BETWEEN THE BARE LUG AND THE PDU OR DCM WHICH COULD CAUSE A DIRECT SHORT IN THE ELECTRICAL SYSTEM.

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2008 THROUGH 2011 ALL AMERICAN, CONVENTIONAL, AND MICRO BIRD SCHOOL BUSES MANUFACTURED FROM DECEMBER 13, 2007 THROUGH JANUARY 18, 2010 EQUIPPED WITH RICON MODEL S OR K SERIES PUBLIC USE WHEELCHAIR LIFTS. THE RESTRAINT BELT ON THESE LIFTS WAS DESIGNED TO PREVENT THE LIFT FROM MOVING, UNLESS THE TONGUE OF THE BELT IS FULLY ENGAGED AND LATCHED IN THE BUCKLE. RICON HAS DISCOVERED, HOWEVER, THAT IT IS POSSIBLE FOR THE OPERATOR TO INSERT THE BELT TONGUE INTO THE BUCKLE WITHOUT FULLY ENGAGING THE LATCHING MECHANISM. IN THIS CASE, THE RESTRAINT BELT WOULD APPEAR TO BE LATCHED, AND THE OPERATOR COULD RUN THE LIFT. IF THE RESTRAINT BELT TONGUE IS NOT FULLY ENGAGED INTO THE RESTRAINT BELT BUCKLE, AND LATCHED, THE LIFT MAY OPERATE WITH AN OCCUPANT ON THE PLATFORM.

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2008 THROUGH 2010 ALL AMERICAN, CONVENTIONAL, AND MICRO BIRD TRANSI BUSES MANUFACTURED FROM DECEMBER 16, 2007 THROUGH DECEMBER 21, 2009 EQUIPPED WITH RICON MODEL S OR K SERIES PUBLIC USE WHEELCHAIR LIFTS. THE RESTRAINT BELT ON THESE LIFTS WAS DESIGNED TO PREVENT THE LIFT FROM MOVING, UNLESS THE TONGUE OF THE BELT IS FULLY ENGAGED AND LATCHED IN THE BUCKLE. RICON HAS DISCOVERED, HOWEVER, THAT IT IS POSSIBLE FOR THE OPERATOR TO INSERT THE BELT TONGUE INTO THE BUCKLE WITHOUT FULLY ENGAGING THE LATCHING MECHANISM. IN THIS CASE, THE RESTRAINT BELT WOULD APPEAR TO BE LATCHED, AND THE OPERATOR COULD RUN THE LIFT. IF THE RESTRAINT BELT TONGUE IS NOT FULLY ENGAGED INTO THE RESTRAINT BELT BUCKLE, AND LATCHED, THE LIFT MAY OPERATE WITH AN OCCUPANT ON THE PLATFORM.

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2010 ALL AMERICAN, CONVENTIONAL, AND MICRO BIRD SCHOOL BUSES MANUFACTURED FROM APRIL 24 THROUGH NOVEMBER 14, 2009 EQUIPPED WITH CERTAIN RICON S SERIES AND K SERIES L-MODEL WHEELCHAIR LIFTS. THERE IS A PROBLEM IN THE SOFTWARE THAT CONTROLS THE LIFT'S "UP" FUNCTION. IF THE "UP" SWITCH IS RELEASED BEFORE THE FLOOR LEVEL LIMIT SWITCH IS ACTIVATED, THE LIFT MAY CONTINUE ITS UPWARD TRAVEL FOR APPROXIMATELY 1 SECOND BEFORE STOPPING. THE CONTINUED UPWARD TRAVEL MAY OVERRUN THE FLOOR LEVEL CUT OFF POINT.

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2010 ALL AMERICAN TRANSIT BUSES MANUFACTURED FROM SEPTEMBER 23 THROUGH NOVEMBER 19, 2009 EQUIPPED WITH CERTAIN RICON S SERIES AND K SERIES L-MODEL WHEELCHAIR LIFTS. THERE IS A PROBLEM IN THE SOFTWARE THAT CONTROLS THE LIFT'S "UP" FUNCTION. IF THE "UP" SWITCH IS RELEASED BEFORE THE FLOOR LEVEL LIMIT SWITCH IS ACTIVATED, THE LIFT MAY CONTINUE ITS UPWARD TRAVEL FOR APPROXIMATELY 1 SECOND BEFORE STOPPING. THE CONTINUED UPWARD TRAVEL MAY OVERRUN THE FLOOR LEVEL CUT OFF POINT.

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2010 ALL AMERICAN SCHOOL BUSES MANUFACTURED FROM MAY 13, 2009 THROUGH FEBRUARY 26, 2010. THE WIRING HARNESS FOR THE REAR TAG LIGHT MAY BE OF INSUFFICIENT LENGTH RESULTING IN THE HARNESS BEING ROUTED IMPROPERLY AND EXPOSING THE CONNECTOR TO THE ENVIRONMENT WHICH COULD CAUSE THE CONNECTOR TO CORRODE. CORROSION COULD CAUSE A DIRECT SHORT IN THE TAG LIGHT CIRCUIT. A SHORT IN THE TAG LIGHT WIRING CIRCUIT, WHICH INCLUDES THE HEADLIGHT LOW BEAM CIRCUIT, COULD CAUSE SUDDEN LOSS OF HEADLIGHT LOW BEAMS.

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A NONCOMPLIANCE IN CERTAIN MODEL YEAR 2010 ALL AMERICAN REAR ENGINE SCHOOL BUSES MANUFACTURED FROM AUGUST 27, 2009 THROUGH JANUARY 25, 2010. ADHESIVE REQUIRED FOR INTERIOR REAR BULKHEAD PANELS WAS OMITTED. THE BUSES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 221, "SCHOOL BUS BODY JOINT STRENGTH."

BLUE BIRD HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2010 ALL AMERICAN REAR ENGINE SCHOOL BUSES MANUFACTURED BETWEEN JANUARY 5, 2009 AND JANUARY 18, 2010. THE BATTERY CABLES MAY HAVE BEEN IMPROPERLY ROUTED AT THE FRONT BOTTOM OF THE LARGE BATTERY COMPARTMENT RESULTING IN THE BATTERY CABLES POTENTIALLY BEING PINCHED BETWEEN THE FRONT BOTTOM OF THE BATTERY COMPARTMENT BOX AND THE EXHAUST MOUNTING BRACKET.