2016 Blue Bird Vision

On March 17, 2023, the Office of Defects Investigation (ODI) opened PE23-004 to investigate instances of drag link separation in model year (MY) 2016-2020 Vision school buses manufactured by Blue Bird Body Company (Blue Bird). Since drag links are serviceable items that can wear out, ODI opened this investigation to understand why two drag links separated at the steering arm end shortly after having passed a routine inspection by multiple qualified entities.Two buses used in the same rural school district, owned and maintained by different bus contractors, had both undergone similar annual and semi-annual inspections prior to the start of the school year.Both failed within a week of each other, approximately a month into the school year. ODI interviewed the bus contractors and surveyed the industry to learn what inspection methods were being used and which ones were best at detecting wear in the components.ODI learned that the failed buses had not been inspected using the most thorough methods. ODI collected the drag links from each of the failed buses. Assisted by the Pennsylvania State Police Motor Carrier Enforcement Division and using best practice inspection methods, ODI identified and collected a pre-separation drag link from a neighboring school district.  The drag links underwent a teardown inspection at the Vehicle Research and Test Center (VRTC) jointly with Blue Bird and THK-Rhythm Automotive, the drag link manufacturer.In all cases, the visual analysis of each drag link end revealed that the grease at the steering arm end was dirty, discolored, and dry in texture, while the pitman arm end was still clean looking and fluid. ODI reviewed the information request data submitted by Blue Bird.No other separations had been reported.ODI contacted additional fleets to determine whether any other separations had occurred that had not been included in the submitted warranty and claim data.None were found. The grease fitting on the steering arm end is obscured by the steering arm itself.Therefore it is believed that inadequate maintenance resulted in the failures that had not been detected during the less-thorough prior inspections.Blue Bird has agreed to issue a notification to all owners to clearly identify all lubrication points and ensure all owners understand the proper lubrication and inspection methods.Blue Bird will also update their service manuals to convey the industry best practices of having someone turn the steering wheel while someone else inspects the drag links while the wheels are on the ground. Since the drag link failures appear to be caused by maintenance and inspection deficiencies and not due to a design, material or manufacturing issue, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances.

SCHOOL BUS DRIVER REPORTED AN OIL LEAK AT THE REAR OF THE LEFT SIDE VALVE COVER. I INSPECTED THE BUS AND SAW A LOT OF OIL ON THE FRAME AREA ON THE LEFT SIDE ENGINE AREA. CHECKED THE VALVE COVER BOLTS FOR TIGHTNESS AND FOUND THE BOLTS TO BE TIGHT. AT THE REAR OF THIS VALVE COVER THE AREA IS VERY TIGHT AND THERE ARE HOSES AND WIRES RAN BETWEEN THE VALVE COVER AND THE FIREWALL. I WAS ABLE TO PHYSICALLY MOVE THESE AND FEEL AROUND THE AREA AND DISCOVERED THAT A HOLE HAS BEEN RUBBED COMPLETELT THROUGH THE FIREWALL, THIS IS WHERE THE OIL IS COMING FROM. AM NOT ABLE TO TAKE CLEAR PICTURES BECAUSE OF THE SPACE CONSTRAINTS. I GOT UNDERNEATH OF THE BUS AND DISCOVERED THAT OIL HAS BEEN GETTING ONTO THE EXHAUST ALSO, THIS SEEMS TO BE A FIRE HAZARD. I HAVE CONTACTED THE DEALER, BUT AT THIS TIME IT IS UNKNOWN IF IT WILL BE COVERED UNDER WARRANTY. THIS BUS IS OUT OF SERVICE UNTIL REPAIRS ARE COMPLETE. *LN *AS

NHTSA ID

11311782

Incident

Feb 24, 2020

Mileage

120,186 mi

FAILURE OF THE PROPORTIONING VALVE WHICH IS CAUSING PREMATURE BRAKE PAD WEAR ON THE REAR. THE VEHICLE HAS AIR DISC BRAKES. WE HAVE SEVERAL IN OUR FLEET THAT HAS THIS ISSUE. WE BROUGHT THE BUS IN FOR SERVICE AND UPON INSPECTING THE BRAKES WE DISCOVERED THE ISSUE. WE HAVE CONTACTED THE COMPANY WE PURCHASED THE BUSES FROM AND I WAS TOLD THEY KNEW THERE WAS AN ISSUE AND THEY HAD A FIX BUT IT WOULD COST US $250. MY QUESTION IS WHO APPROVED THE FIX AND WHERE CAN I FIND IT IN WRITING. THEY ARE NOT REPLACING THE VALVE, THEY ARE PUTTING ON A QUICK RELEASE VALVE IN THE REAR.

NHTSA ID

11110684

Incident

Jul 10, 2018

Mileage

30,000 mi

Uploading documents that will be sent out to customers to educate them about draglink maintenance.

Uploading documents that will be sent out to customers to educate them about draglink maintenance.

Cummins recently issued Temporary Repair Practice (TRP2484) for certain vehicles with DEF sensor failures in which DEF sensor replacement parts are not available. This provides a temporary ECM calibration that inhibits engine warning messages for communication errors with the DEF sensor allowing continued operation without engine derate. Regulators are allowing for this temporary calibration to be loaded in the engine ECM by a Cummins authorized repair location if the DEF sensor fails. This temporary calibration does not repair the failure therefore a final repair must be performed and the original calibration be re-installed. Field Service has been requesting an ECM image be uploaded within the support ticket as part of the diagnostics and is carried over into Service Update 2201 (SU2201). In order to receive an authorization code and utilize Cummins TRP2484, you must follow the process, as outlined in SU2201. The specific component affected is Assembly Code: 35-300 Emissions Components.

Overview: Certain 2013 through 2022 model year Blue Bird Vision School and Non-School Bus units has experienced signs of single strand failing, leading to multiple stands, and eventually belt failure. The belt composition is not ideal for the life cycle of the bus. This Service Bulletin will provide owners with a one-time new replacement belt with the more durable material that is currently being used in production and for service. This Service Bulletin is for part cost coverage only. No labor reimbursement will be provided. Affected Units: Blue Bird Body Company is voluntarily issuing a service bulletin for the following: o Certain model year 2013 through 2022 Blue Bird Vision School Buses omanufactured from January 10, 2012 through February 26, 2021 o Certain model year 2013 through 2022 Blue Bird Vision Non-School Buses omanufactured from November 20, 2012 through November 19, 2020 Repair Parts: The Parts List outlined in the S21AZ Instructions details the part required to perform Service Bulletin S19AZ and should be ordered through Blue Bird Service Parts. The belt is based on the engine generation. Parts are currently available. Time Allowance: No labor will be provided to replace the belt with a more durable material belt, per the published Service Bulletin instructions.

This SKU is a DEF Injector. The customer communication requested return of unsold inventory to inspect the sealing. The injector sealing may have an issue which will cause a slow leak. A slow leak of the DEF Injector can lead to crystal formation which can cause aftertreatment related fault codes and ECU driven engine derating.

The intent of Service Memorandum SM2001 is to “Announce a New Blue Bird Dealer Process” now available to perform a Ford Powertrain Control Module (PCM) modification remotely at the dealer service center location. This modification will be done using the Roush Diagnostic Tool (RDT). The RDT software version 10.04.0011 or higher is required.