1993 BLUE BIRD TC2000 recalls

THE FRONT BRAKE AIR LINES ARE INCORRECTLY ROUTED THROUGH THE PRESSURE PROTECTION VALVE AT THE AUXILIARY WET TANK. THIS RESULTS IN LACK OF AIR PRESSURE TO THE FRONT BRAKES WHEN THE AIR PRESSURE IN THE AUXILIARY WET TANK DROPS BELOW 65 P.S.I., RESULTING IN INOPERABLE FRONT BRAKES.

WHEN THERE IS NO FRONT BRAKE APPLICATION, STOPPINGDISTANCE INCREASES, AND THERE IS AN INCREASED RISK OF ACCIDENT.

CORRECTLY REROUTE THE BRAKE LINES.

VEHICLE DESCRIPTION: SCHOOL AND TRANSIT BUSES EQUIPPED WITH COMPRESSED NATURAL GAS ENGINES (CNG). THE ORIGINAL PRESSURE RELIEF DEVICES MAY VENT UNEXPECTEDLY.

COMPRESSED NATURAL GAS LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE OR EXPLOSION.

DEALERS WILL REPLACE THE PRESSURE RELIEF DEVICES.

VEHICLE DESCRIPTION: SCHOOL BUSES. THESE BUSES FAIL TO MEET THE 60 PERCENT JOINT STRENGTH REQUIREMENTS OF FMVSS NO. 221, "SCHOOL BUS BODY JOINT STRENGTH."

IN THE EVENT OF A VEHICLE CRASH, THE ROOF MAY NOT BE SUPPORTED SUFFICIENTLY, CAUSING PERSONAL INJURY TO BUS OCCUPANTS.

OWNERS WILL BE CONTACTED AND ADVISED TO INSPECT EACH ROOF JOINT. OWNERS WILL INSTALL REPAIR RIVETS IN EACH JOINT FOUND TO HAVE INSUFFICIENT QUANTITY OF RIVETS IN EACH EXAMINED 8 INCH SECTION.

CERTAIN SCHOOL BUSES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 221, "SCHOOL BUS BODY JOINT STRENGTH." ONE OR MORE OF THE BOLTS ATTACHING THE DRIVER'S PLATFORM TO THE FLOOR STRUCTURE WAS OMITTED.

THE REAR OF THE DRIVER'S PLATFORM MAY NOT BE PROPERLY RETAINED IN THE EVENT OF A CRASH WHICH COULD INCREASE THE RISK OF INJURY OR DEATH TO PASSENGERS.

BLUE BIRD WILL NOTIFY ITS CUSTOMERS AND INSPECT AND REPAIR THE AFFECTED UNITS. OWNER NOTIFICATION BEGAN ON NOVEMBER 20, 2003. 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 478-822-2242.

AIR SUSPENSION TORQUE ARM CAN COME IN CONTACT WITH THE AIR BRAKE CHAMBER MOUNTING BRACKET RESULTING IN BROKEN S-CAM MOUNTING BRACKET.

THIS CAN RESULT IN THE LOSS OF BRAKE LINING CONTACTON THE REAR WHEEL INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

DEALERS WILL MODIFY VEHICLES TO INCORPORATE AN AXLE SEAT SPACER AND REPLACE THE CAM SHAFT AND CAM SHAFT BRACKET WITH A LONGER CAM SHAFT AND CAM SHAFT BRACKET ON BOTH RIGHT AND LEFT REAR BRAKE ASSEMBLIES TO PROVIDE SUFFICIENT CLEARANCE.

THESE UNITS ARE EQUIPPED WITH A COUNTER WEIGHT ASSEMBLY MADE UP OF 300 POUNDS OF 1/4" PLATE STEEL WELDED TOGETHER AND BOLTED BETWEEN THE FRAME RAILS IN THE REAR OVERHANG JUST FORWARD OF THE REAR BUMPER. SOME OF THE WELDS HAVE BROKEN DUE TO INSUFFICIENT WELDS, CORROSION, OR ICE EXPANSION.

THESE PLATES CAN DROP TO THE ROADWAY BECOMING A HAZARD TO FOLLOWING VEHICLES INCREASING THE POTENTIAL FOR AN ACCIDENT.

DEALERS WILL INSTALL A MECHANICAL RETAINING DEVICE WHICH CLAMPS THE PLATES TOGETHER AND FASTENED WITH THREADED FASTENERS. BUS OWNERS WILL HAVE THE OPTION OF REPAIRING THEIR OWN VEHICLES.

AN INCORRECT SIZE BRAKE CHAMBER MAY HAVE BEEN INSTALLED ON THE FRONT AND/OR REAR BRAKE ASSEMBLIES WHICH COULD AFFECT THE BRAKE BALANCE AND STOPPING DISTANCE.

BRAKE IMBALANCE MAY CAUSE LOSS OF VEHICLE CONTROL DURING BRAKE APPLICATIONS; INCREASED STOPPING DISTANCE OR BRAKE APPLICATION COULD RESULT IN LOSS OF CONTROL AND AN ACCIDENT.

BUS OWNERS WILL BE PROVIDED WITH INSTRUCTIONS TO INSPECT THEIR VEHICLES AND PROVIDE BLUE BIRD WITH CERTAIN INFORMATION. BLUE BIRD WILL REVIEW THE INFORMATION AND, WHERE NEEDED, WILL FORWARD REPLACEMENT BRAKE CHAMBERS ALONG WITH REPLACEMENT INSTRUCTIONS TO THE VEHICLE OWNERS. BRAKE CHAMBER REPLACEMENT WILL BE PERFORMED BY THE VEHICLE OWNER OR A QUALIFIED REPAIR FACILITY.

VEHICLE DESCRIPTION: SCHOOL BUSES. THE WALL SIDE ATTACHING BOLTS FOR SOME OF THE PASSENGER SEATS MAY HAVE BEEN INSTALLED TOO CLOSE TO THE EDGE OF THE SEAT LEDGE AND IN THE WRONG ATTACHING HOLE RESULTING IN WEAKENING OF THE SEAT LEDGE AT THE ATTACHMENT POINTS.

IN THE EVENT OF A FRONTAL CRASH, THE REAR ATTACHING BOLT OF THESE SEATS COULD PULL OUT OF THE SEAT LEDGE INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.

BLUE BIRD WILL FURNISH TO DISTRIBUTORS AND OWNERS, PARTS AND INSTRUCTIONS NECESSARY TO STRENGTHEN THE PASSENGER SEAT ATTACHMENT AT THE WALL SIDE.

PASSENGER'S CLOTHING CAN UNKNOWINGLY BECOME CAUGHT IN THE FORWARD HANDRAILS AT BUS DOORS WHEN EXITING THE BUS.

WHEN A PASSENGER'S CLOTHING BECOMES CAUGHT IN THE HANDRAIL, AND THE BUS DRIVER CLOSES THE DOOR AND PUTS THE VEHICLE IN MOTION, THE INDIVIDUAL IS SUBJECT TO BEING DRAGGED BY THE BUS. THIS CAN RESULT IN SERIOUS INJURY OR DEATH.

OWNERS WILL BE DIRECTED TO REMOVE ALL FORWARD HANDRAILS. PROVISIONS WILL BE MADE FOR THOSE OWNERS OPERATING IN STATES WHICH MANDATE A FORWARD HANDRAIL THAT A REPLACEMENT HANDRAIL WILL BE PROVIDED.

A GAP BETWEEN THE MASTER CYLINDER AND REMOTE BRAKE FLUID RESERVOIR ADAPTER, CAUSED BY AN OUT-OF-SPECIFICATION CONDITION OF THE ADAPTER, RESULTS IN BRAKE FLUID LOSS DURING BRAKE APPLICATION.

BRAKE FLUID LOSS RESULTS IN LOSS OF PRESSURE CAUSINGPARTIAL LOSS OF BRAKING ABILITY, WHICH MAY LEAD TO AN ACCIDENT.

REPLACE THE OUT-OF-SPECIFICATION ADAPTERS.

PASSENGERS CLOTHING CAN UNKNOWINGLY BECOME CAUGHT IN THE HANDRAILS AT BUS DOORS WHEN EXITING THE BUS.

WHEN A PASSENGER'S CLOTHING BECOMES CAUGHT IN THE HANDRAIL, AND THE BUS DRIVER CLOSES THE DOOR AND PUTS THE VEHICLE IN MOTION,THE INDIVIDUAL IS SUBJECT TO BEING DRAGGED BY THE BUS. THIS CAN RESULT INSERIOUS INJURY OR DEATH.

DEALERS WILL INSTALL A SET SCREW TO THE METAL CLAMP WHICH RETAINS THE INTERMEDIATE HANDRAIL. A HIGH IMPACT MOLDED PLASTIC "CLAM SHELL" WILL BE PLACED OVER EACH END OF THE INTERMEDIATE HANDRAIL COMPLETELY COVERING THE CLAMP AND ELIMINATING ALL CATCH-POINTS. THE FLANGE OF THE EXISTING FLOOR LINE BRACKET WILL BE CRIMPED SECURING THE VERTICAL SECTION OF THE PRIMARY TUBLAR HANDRAIL AT THE FLOOR LINE.

VEHICLE DESCRIPTION: FRONT AND REAR ENGINE SCHOOL BUSES EQUIPPED WITH 60 GALLON SIDE MOUNTED FUEL TANK BARRIERS. THESE BUSES DO NOT COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 301, "FUEL SYSTEM INTEGRITY."

IN THE EVENT OF A VEHICLE CRASH, THE FUEL TANK COULD BE DAMAGED, LEAKING FUEL, POSSIBLY RESULTING IN A VEHICLE FIRE.

BLUE BIRD WILL SHIP INSTRUCTIONS AND MODIFICATION KITS TO THE OWNERS OF THESE BUSES.

THE AISLE SIDE STYROFOAM KNEE PADS ON THE SUBJECT BARRIERS ARE 11" WIDE AND NOT 14.5" AS REQUIRED BY FMVSS NO. 222, "SCHOOL BUS PASSENGER SEATING AND CRASH PROTECTION."

CONSEQUENCE OF NON-COMPLIANCE: THIS CONDITION COULD INCREASE THE POTENTIAL FOR INJURY IN A VEHICLE ACCIDENT.

DEALERS WILL REPLACE THE INCORRECT PAD WITH THE CORRECT 14.5" KNEE PAD.

VEHICLE DESCRIPTION: SCHOOL BUSES EQUIPPED WITH BOSTROM DRIVER'S SEAT MODEL F222 OR BOSTRUM "ROUTEMASTER" SEAT. BLUE BIRD OPTION 2821 OR 2824. THE SEAT PEDESTALS ARE FATIGUE CRACKING ADJACENT TO THE WELD WHICH SECURES THE PEDESTAL'S UPPER PLATE TO THE UPPER, TELESCOPING PORTION OF THE ADJUSTABLE COLUMN SUPPORT.

THE UPPER MOUNTING PLATE AND SEAT UPPER GRADUALLY BECOMES LOOSE RESULTING IN THE UPPER PLATE DETACHING FROM THE SUPPORTING COLUMN AND THE SEAT CAN FALL FROM ITS MOUNTING. THIS CAN RESULT IN PERSONAL INJURY TO THE DRIVER.

DEALERS WILL REPAIR THESE PEDESTALS WITH A NEWLY DESIGNED PEDESTAL BRACKET KIT.

THE HYDRAULIC HOSES WHICH INTERCONNECT WITH THE HYDRAULIC PUMP, HYDRAULIC RADIATOR FAN MOTOR AND POWER STEERING GEAR HAVE AN UNDERSIZED WIRE MESH CORE WHICH RESULTS IN AN IMPROPER HOSE END CRIMP. THE IMPROPER CRIMP CAN CAUSE A LEAK, EMPTYING THE POWER STEERING HYDRAULIC FLUID RESERVOIR, RESULTING IN LOSS OF POWER STEERING ASSIST.

COMPLETE LOSS OF POWER STEERING ASSIST CAN CAUSE LOSS OFVEHICLE CONTROL AND RESULT IN AN ACCIDENT.

OWNERS ARE BEING ASKED TO INSPECT HOSE FOR THE DATE CODE 3-1Q93 WHICH IS EMBOSSED ON THE HOSE COVER EVERY 18 INCHES. REPLACEMENT HOSES WILL BE PROVIDED. OWNERS CAN HANDLE THE REPAIR THEMSELVES OR HAVE A BLUE BIRD DISTRIBUTOR ASSIST THEM. OWNERS WILL BE REIMBURSED FOR THE LABOR CHARGES FOLLOWING COMPLETION OF THE RECALL WORK.