2006 Blue Bird Wanderlodge M450 Lxi

As detailed in the opening resume for this investigation dated November 16, 2015, Blue Bird Corporation (BBC) conducted recall 07V-586 with two subsequent amendments to address overloaded front axles and tires on the subject vehicles.Following the remedy installations, NHTSA received nine petitions and seven consumer complaints (many from the same owners who had filed petitions) alleging the remedial actions taken by BBC were inadequate.At the time, NHTSA was aware of two consumer complaints and three crashes of vehicles that received the 07V-586 recall remedy.One of the complaints was similar to the petitions in that it focused on utility loss and not safety issues.The second complaint (received May 2014) described a crash that occurred in May 2013 that was also identified in media reports. The second and third crashes occurred in August 2013 and January 2015. All three crashes allegedly resulted from failure of one of the front tires.During this investigation, NHTSA requested information from BBC including details about the three referenced crashes and if they were aware of any additional failures.BBC responded that they were not aware of any other failures and had only received crash information on one of the incidents from sources other than NHTSA.In order to understand why the tires failed prior to or during each of the three crashes, NHTSA attempted to collect as much information about each incident as possible.This included insurance documents, photographs, police accident reports, vehicle weights, maintenance history, and the failed tires.In the case of two of the crashes, not enough information could be obtained to determine the exact cause of the tire failure and crash.In the case of the third crash, the tire was collected and analyzed.This analysis found that the tire failed as a result of impact damage and not overloading.In October 2015, BBC initiated a customer service campaign (S15YF) where owners would be notified that BBC would replace the front wheels and tires on the subject vehicles.This action was taken to address owner concerns that the ride comfort in the vehicle was bad and that tire pressure was difficult to maintain at the required 130psi.The new wheels and tires installed by BBC increased the load capacity of the tire, allowing owners to carry the maximum load of the coach at a lower tire pressure.At the time of the closing of this investigation, NHTSA does not have the necessary evidence to establish the existence of an unreasonable risk to motor vehicle safety in the subject vehicles.NHTSA is not aware of any front axle failures in the subject vehicles for any reason. The single tire failure crash where sufficient evidence had been preserved resulted from the vehicle striking an object damaging the tire.The action taken by BBC to increase the load capacity of the tires on the subject vehicles addresses the safety concerns prompting this investigation.This investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that no safety-related defect exists.The agency may take further action if warranted by the circumstances.

On December 11, 2007, Blue Bird Corporation (BBC) submitted an uninfluenced recall 07V-586 to the agency.This recall described a defect on fifty eight 2005?2007 Model Year (MY) Wanderlodge Recreational Vehicles (RV) where the curb weight of the front axle could exceed the axle?s 16,000 pound rating. To address the issue, BBC replaced the tie rods on the vehicle to a more robust version increasing the rating of the front axle to 17,000 pounds.In addition, BBC relocated a generator rearward from the front of the vehicle and provided updated storage bay weight limit placards forinstallation in each of the vehicles three storage bays.On March 11, 2008, BBC submitted an amendment to the 07V-586 recall.In this amendment, BBC added three more remedial actions to the original recall.In addition to the original recall remedies, BBC would replace the front tires (with the same model tires) perform a front end alignment, and add new tire data placards instructing operators to maintain the vehicle tire pressure at 130 psi (the maximum tire pressure for that model tire).Following receipt of a consumer complaint (10226544) alleging that some of the vehicles subject to recall 07V-586 had front axle curb weights in excess of 17,000 pounds and that operators did not have a reasonable way to maintain tire pressures at 130 psi (as required by recall 07V-586), NHTSA opened Recall Query RQ08-004.The recall query was(Continued on page 2)

BLUE BIRD IS IMPLEMENTING VARIOUS WEIGHT REDUCTION, WEIGHT REDISTRIBUTION , AND CAPACITY UPGRADE INITIATIVES TO IMPROVE THEFRONT AXLE / TIRE OVER-LOAD CONDITION OF THE AFFECTED VEHICLES.ODI IS PRIMARILY CONCERNED ABOUT BLUE BIRD'S INITIATIVE TO UPRATE THE FRONT TIRE BY REQUIRING OWNERS TO MAINTAIN 130 PSI INFLATION PRESSURE.IN RESPONSE TO ODI'S CONCERNS, BLUE BIRD WILL SUPPLEMENT THEIR ORIGINAL REMEDY PLAN OF PROVIDING NEW FRONT TIRES AND NEW TIRE CERTIFCATION LABELS SPECIFYING THE 130 PSI INFLATION REQUIREMENT WITH INTIATIVES TO: (1) INSTALL AN ON-BOARD TIRE INFLATION SYSTEM CAPABLE OF PROVIDING 130 PSI; (2) INSTALL A PLACARD ON THE DASH PANEL AS A ONGOING REMINDER TO OWNERS OF THE NEED TO MAINTAIN PROPER INFLATION PRESSURE; AND (3) INVESTIGATING THE POSSIBLITY OF PERIODICALLY REMINDING OWNERS OF THE IMPORTANCE OF MAINTAINING SPECIFIED TIRE PRESSURE.ODI REMAINS GENERALLY CONCERNED ABOUT FRONT TIRES INSTALLED IN MOTOR HOMES BECAUSE ODI'S EXPERIENCE HAS SHOWN THAT MOTOR HOME OWNERS ARE FREQUENLTY UNABLE OR UNWILLING TO MAINTAIN HIGH INFLATION PRESSURES IN THEIR TIRES.SEE ODI'S CLOSING REPORT FOR ADDITIONAL OBSERVATIONS / DETAILS REGARDING THIS.

TL* THE CONTACT OWNS A 2006 BLUE BIRD WANDERLODGE M450 LXI RV. IN 2010, THE RV RECEIVED A PARTIAL REPAIR ACCORDING TO NHTSA CAMPAIGN NUMBER: 07V586000 (POWER TRAIN). IN 2016, THE OTHER PORTION OF THE REMEDY WAS PERFORMED, WHICH INCLUDED THE APPROPRIATE REPLACEMENT OF THE FRONT TIRES. THE STEERING WHEEL STUDS WERE ALSO REPLACED. THE CONTACT WAS DISPLEASED THAT HE WAS RESPONSIBLE FOR THE LABOR COST, WHICH WAS NOT MENTIONED IN THE RECALL. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ID

10852013

Incident

May 11, 2010

BLOWN LEFT FRONT TIRE CAUSED LOSS OF STEERING, IMPACT LEFT FRONT OF COACH IN THE CENTER DIVIDER. $87000.00 DAMAGE. THIS COACH IS STILL OUT OF SERVICE AT THIS WRITING. THIS COACH HAS HAD ALL PHASES OF CAMPAIGN 07V-586 BLUEBIRD BODY COMPANY. THIS CAMPAIGN IS DESIGNED TO ADDRESS FRONT AXEL WEIGHT ISSUES. I MADE 3 TRIPS OVER A 1 YEAR PERIOD TO ADDRESS CONCERNS OF BLUEBIRD TO MEET TARGET WEIGHT. LOSS OF SERVICE 6 WEEKS TOTAL. NEW MICHELIN TIRES(SPECIFIED IN CAMPAIGN) JUST LESS THAN 5 YEARS OLD WHEN FAILURE OCCURRED. ALL WHEEL POSITIONS HAD REQUIRED PRESSURE MAINTAINED. CONDITION OF COACH WAS PERFECT, STORED IN TEMPERATURE CONTROLLED BUILDING. *TR

NHTSA ID

10594501

Incident

May 31, 2013

Mileage

42,000 mi

CONSUMER STATES REPLY TO RESPONSE BY BLUE BIRD TO REQUEST DEFECT PETITION. *TGW THE CONSUMER STATED THE DEFECT IS THE UNDER CAPACITY OF THE FRONT AXLE. THE TRUE FIX, WHICH WAS INITIALLY OFFERED WAS A R REPLACEMENT AXLE. AS A COST SAVING MEASURE, THE NEW AXLE PLAN WAS SCRAPED AND THE RECONFIGURATION OF THE COACH WAS PLANNED. *JB UPDATED 10/25/12

NHTSA ID

10318626

Incident

Jan 1, 1901

PETITION FOR THE INCOMPLETE, UNSAFE REPAIRS AND MODIFICATION TO THE 2006 BLUE BIRD WANDERLODGE 450 LXI THAT ARE BEING DONE IN AN ATTEMPT TO REMEDY THE CONDITIONS FOR THE NHTSA RECALL 07V586000. *NJ THE ORIGINAL RECALL STATED THE FRONT AXLE WAS OVERWEIGHT ON THE FRONT AXLE WITHOUT CARGO, BUT WITH THE STANDARD 4 PASSENGERS AND FULL WATER. BLUEBIRD STATED THE TIRES SHOULD HAVE 130 PSI, BUT MICHELIN STATED IS SHOULD BE 120 PSI. MICHELIN STATED IF 130 PSI WAS PUT IN EACH TIRE THEY WOULD BLOW OUT EASILY. IN DOING THE MANY LEVELS OF FIXING THE RV, BLUE BIRD FOUND IT NECESSARY TO REDUCE THE NO CARGO WEIGHT OF THE MOTOR HOME IN ORDER TO SHOW APPARENT DECREASED FRONT AXLE LOAD AND TO SHOW SOME CAPACITY IN THE STORAGE COMPARTMENTS. THE UNLOADED WEIGHT HAS BEEN REDUCED TO A NON-STANDARD, 2 PASSENGER AND 1/2 TANK FRESH WATER. SOME OF THE RV'S THAT ARE BEING RELEASED AS FIXED ARE OVERWEIGHT ON THE FRONT AXLE WHEN THEY ARE WEIGHED WITHOUT CARGO BUT HAVE 4 PASSENGERS AND FULL WATER.

NHTSA ID

10292809

Incident

Jan 1, 1901

FAILURE IN THE ATTEMPTS TO REMEDY RECALL 07V586000. *TR THE TIE ROD WEAKNESS WAS NOT A CAUSE OF THE RECALL, BUT WAS A RESULT OF THE NEED TO INCREASE THE AXLE RATING. THE TIE RODS WERE SAFE AT AN AXLE LOAD OF 16,000LBS AND NO TIE ROD RECALL WOULD HAVE OCCURRED IF THE 16,000LB AXLE WAS SUFFICIENT AS ORIGINALLY DESIGNED. THE RECALL WAS BASED ON THE AXLE BEING IN EXCESS OF ITS RATING AND THE MOTORHOME COULD NOT BE SAFELY USED WITH REASONABLE LOADING. SOME OF THE COACHES THAT ARE BEING RELEASED AS FIXED ARE OVERWEIGHT ON THE FRONT AXLE WHEN THEY ARE WEIGHED WITHOUT CARGO, BUT HAVE 4 PASSENGERS AND FULL WATER. THIS OVERWEIGHT STATE WOULD SATISFY THE CONDITIONS AND CAUSE OF THE INITIAL RECALL. UPDATED 11/04/09

NHTSA ID

10289185

Incident

Oct 20, 2009

TL*- THE CONTACT OWNS A 2006 BLUE BIRD WANDERLODGE LXI. THE CONTACT STATED THAT HE WAS NOTIFIED MARCH 2008 ABOUT RECALL 07V586000 ABOUT AXLE WEIGHT LIMIT. THE MANUFACTURER SENT SOMEONE TO REPLACE THE FRONT TIRES AND TOLD HIM TO HAVE THE VEHICLE ALIGNED AND WEIGHED. HE DID THIS AND RETURNED THE VEHICLE TO THE MANUFACTURER'S POSSESSION. HE MADE SEVERAL DIFFERENT TRIPS TO THE MANUFACTURER WHO FINALLY REPAIRED THE VEHICLE. HOWEVER, HE WAS STILL HAVING THE SAME EXCESSIVE WEIGHT ISSUE. MOST RECENTLY, THE MANUFACTURER WENT OUT OF BUSINESS. HE WAS NEVER GIVEN FINAL WEIGHT MEASUREMENTS. THE CURRENT MILEAGE WAS APPROXIMATELY 17,000. THE FAILURE MILEAGE WAS APPROXIMATELY 12,000.

NHTSA ID

10266596

Incident

Mar 18, 2008

Mileage

12,000 mi

SIR, THIS A COMPLAINT ABOUT THE PUBLICATION OF THE RECALL NHTSA CAMPAIGN ID NUMBER : 07V586000. AS YOUR SITE INDICATES THAT CCW AND BLUE BIRD KNEW OF AN OVERWEIGHT ISSUE IN SEPT.2007. THE RECALL OF DECEMBER 2007 BASED ON A TIE ROD WEAKNESS APPEARS TO BE A DIVERSION FROM THE UNSAFE AND IMMEDIATE PROBLEM OF SIGNIFICANTLY OVERWEIGHT FRONT AXLE AND THE RV'S WERE STILL ALLOWED TO BE DRIVEN. TWO OF THESE VEHICLES HAVE CRASHED WITH FRONT TIRE FAILURES: BOTH WRITE-OFFS AND ONE FATAL. THE UPDATED SUMMARY DOES NOT YET SHOW THE EXTENT AND DANGER OF THE VEHICLE. THE AMENDED DEFECT NOTICE(PART 573) - 3-11-2008 SHOWS AN INVALID REMEDY AS THE FRONT AXLE WEIGHT IS OVER 17,000 POUNDS IN MANY CASES. ONLY THE ATTACHMENTS IN THE OWNER NOTIFICATION LETTER(PART 577) SHOW THE EXTENT OF THE PROBLEM. THE SUMMARY SHOULD HAVE MORE INFORMATION THAT OVERWEIGHT IS THE MAJOR CONCERN AND THAT A NEW 18,000 POUND AXLE IS BEING DESIGNED AND IS REQUIRED. IT SHOULD ALSO BE POINTED OUT THAT THE 315/80X22.5 TIRES ARE MINIMUM FOR A 17,000 POUND AXLE. A 4% PRESSURE DROP TO 124 PSI IS INSUFFICIENT FOR THE 17000 POUND LOAD. NOTE THAT INTERNAL RV AIR SYSTEMS AND MOST SERVICE STATIONS CANNOT GO OVER 120 PSI. SINCERELY, ROSS MACKILLOP *TR

NHTSA ID

10226544

Incident

Dec 11, 2007

New Blue Bird Support Center - Technical Bus Support: Dealer memo to announce the new on-line Blue Bird Support Center for technical bus support requests.

Blue Bird Troubleshooting Guides: Blue Bird announcement of the addition of troubleshooting guides for assisting in the service of the Blue Bird products. These troubleshooting guides are available on the Vantage website.

BLUE BIRD: ON CERTAIN MODEL BUSES, PROCEDURE INFORMATION IS PROVIDED WHERE BY MOISTURE MUST BE PURGE FROM ACCESSORY AIR SYSTEM. *PE

BLUE BIRD: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. INFORMATION PROVIDED REGARDING AFFECTED UNITS WITH A POTENTIAL FOR REDUCTION IN POWER TO OPERATE COACH ACCESSORIES IF COACH IS NOT CONNECTED TO SHORE POWER TO HAVE CIRCUIT BOARDS REPLACED. *PE