2004 Blue Bird Ultra LF Problems, Complaints & Recalls

Problem: 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.

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

Fix: 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.

Problem: Blue Bird Corporation is recalling certain model year Ultra LF transit buses manufactured March 14, 2003, through March 12, 2007. Cracks may develop in the bracket which secures the power steering gear to the bus frame.

Risk: If left unchecked, the cracks may propagate and cause a separation of the steering gear from the bus frame. This would result in a loss of steering control, possibly increasing the risk of a vehicle crash.

Fix: Blue Bird will notify owners, and dealers will install reinforcement plates, free of charge. The recall began on March 20, 2013. Owners may contact Blue Bird at 1-478-825-2021.

Problem: Certain commercial series transit buses equipped with cummins isb-02 diesel engines built with emc controlled fuel lift pumps. Erratic voltage supply to the fuel lift pump causes premature electric brush wear internal to the fuel lift pump. This premature wear could result in fuel lift pump failure and in some cases may cause an engine stall condition.

Risk: Should the engine stall, a vehicle crash could occur.

Fix: Cummins, in conjunction with blue bird, will notify owners and repair the engines by emc recalibration and replacement of the fuel lift pump at no charge to the customer. Owners may contact cummins assistance center at 1-800-diesels or blue bird at 1-478-822-2242.

Problem: On certain commercialtransit buses equipped with vapor door assemblies, the two piece curved connecting rods when used as an element of the door actuation linkage in conjunction with a vapor medium pneumatic differential engine, may be subject to fatigue failure resulting in bending or breaking of the connecting rod.

Risk: A broken connecting rod can allow the door panel to move freely in an uncontrolled manner, leaving passengers inside the vehicle unprotected by the door panel and enabling a protruding door panel to strike persons or objects outside the vehicle.

Fix: Blue bird is working with vapor bus international to notify owners and have the repair performed on their vehicles. The remedy consists of replacing the two piece connecting rod with a one piece connecting rod. The recall began on october 18, 2005. Owners may contact blue bird at 478-822-2242 or vapor at 847-777-6400.

Problem: Certain transit buses fail to comply with the requirements of federal motor vehicle safety standard no. 217, "bus emergency exits and window retention and release." the striker plates at the bottom of the emergency pushout windows can wear a groove into the emergency release bolt. If this groove becomes deep enough, the emergency push window may fail to open as intended when released.

Risk: In the event of an emergency, failure of the pushout window could potentially trap passengers or delay their escape, increasing the risk of injury.

Fix: Dealers will ship repair parts and installation instructions to the bus owners. The recall began on february 21, 2005. Owners may contact blue bird at 478-825-2021.

Problem: 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.

Risk: A potential fire in the wheel may occur which may result in property damage or personal injury.

Fix: 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.