Roof Hatch External Handle May Break/FMVSS 217 – 2018-2020 Blue Bird Vision & All American School Buses

July 12, 2019 NHTSA CAMPAIGN NUMBER: 19V526000

Roof Hatch External Handle May Break/FMVSS 217

If the roof hatch external handle breaks, in the event of an emergency, the hatch cannot be easily opened from outside the vehicle, increasing the risk of injury.

 

NHTSA Campaign Number: 19V526

Manufacturer Blue Bird Body Company

Components STRUCTURE

Potential Number of Units Affected 1,667

 

Summary

Blue Bird Body Company (Blue Bird) is recalling certain 2018-2020 Vision and All American school buses equipped with Specialty Manufacturing Prolo roof emergency exit hatches. Due to a manufacturing issue, the roof hatch external handle may unexpectedly break under reasonable use. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 217, “Bus Emergency Exits and Window Retention and Release.”

 

Remedy

Blue Bird will notify owners, and Specialty dealers will replace the outer handle, free of charge. The recall began August 21, 2019. Owners may contact Blue Bird customer service at 1-478-822-2242. Blue Bird’s number for this recall is R19AF – SB.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

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Rappel Blue Bird R19AF

WORK INSTRUCTION

PROLO OUTER HANDLE REPLACEMENT

Control No: W-HAT-180

Content Revision: B

Dept: PROLO HATCH

 

1. PURPOSE: How to replace the 009336 Outer Handle for a 924X Series Prolo Roof Hatch.

2. SAFETY: Wear safety glasses all the time on the production floor.

3. WORK INSTRUCTION:

 

Step 1: Gather the necessary components for the work. 009336 Handle, 009321-5 O-ring, 008798 Screw, 1/8” Allen wrench or driver w/ 1/8” bit

 

Step 2. Locate the silver “build date” sticker on the inside of the lid (located in red circle shown above)

 

Step 3: If the date is between 8-1-18 and 5-21-19, the hatch will need to be reworked. Dates before or after that timeframe do not need rework.

 

Step 4: REWORKING THE HATCH

Rotate the handle into the orientation shown

 

Step 5: Set the torque setting to 45, or the minimum needed to set the screw.

 

Step 6: Insert the 1/8” Allen bit into the 008798 screw and remove screw from red handle.

 

Step 7: Pull down to remove the red handle

 

Step 8: Open the lid 5-6 inches, reach around and lift the black handle out of the bushing.

 

Step 9: Remove outer handle

 

Step 10: Ensure that the 009321-5 Oring is secured around the base of the handle stem. If it is not there, check to see if it is in the lid bushing. If it is not in either location, replace with a new o-ring.

 

Step 11: Insert the new handle into the bushing and orient as shown.

 

Step 12: From inside the lid, you will see the shaft of the outer handle

 

Step 13: The inside of the red handle has ribs to self-orient the red handle on the outer handle.

 

Step 14: Place the handle onto the stem of the outer handle (oriented as shown).

 

Step 15: Insert the 008798 screw into the red handle and thread the screw into the outer handle stem.

Approximately 10-12 in-lbs to secure. Setting of 4-5 on driver

 

Step 16 Close the lid from the vented position. The rework is complete.

Move to the other hatch in the bus.

 

4. DOCUMENT HISTORY (UP TO 5 REVISIONS ONLY)

Revision Level	Section(s)	Summary of Significant Changes
–	NA	Initial Release
A	All	Added steps 3, 5, 19 and 20; updated image on current step 18
B	3	Removed Steps 17-20

 

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R19AF

IMPORTANT SAFETY RECALL NOTICE

NHTSA Recall Number:   19V-526 (School Bus)
NHTSA Recall Number:   19V-524 (Non-School Bus)

 

DATE: August 21, 2019

Dear Blue Bird Owner:

SUBJECT: RECALL R19AF, Safe Fleet Prolo Roof Hatch Handle

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

This important safety recall notice applies to your bus(es) identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet. If you no longer own the subject bus(es), please complete the appropriate section of the yellow cover sheet and return to Blue Bird in the enclosed pink postage prepaid envelope.

Blue Bird Body Company and Specialty Manufacturing, Incorporated (SMI) are recalling certain model year 2018 and 2020 Vision School Buses manufactured from September 7, 2018, through July 10, 2019; certain model year 2018-2020 All American School Buses manufactured from September 10, 2018, through June 30, 2019; certain Vision 2020 Non-School Buses manufactured from November 15, 2018, through May 31, 2019; and a 2020 All American Non-School Bus manufactured on November 1, 2018.

On the subject buses, Blue Bird and Specialty Manufacturing, Incorporated (SMI) have determined that some Prolo Hatches may contain defects (voids/porosity) in the outside release handle that have resulted from the casting process.  Excess voids and porosity may create failure points in the handle that can lead to breakage under reasonable use.  Failure of the external release handle will prevent the hatch release mechanism from being actuated from outside the vehicle.  The hatch can still be opened from the outside by venting the hatch and actuating the inside release handle, however, this operation is not intuitive and not detailed in the required instructions located on the hatch.  Failure of the external release handle does not prevent actuation of the release mechanism from inside the vehicle.  Blue Bird and SMI have determined these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 217, Bus Emergency Exits and Window Retention and Release.  If the roof hatch external handle breaks, in the event of an emergency, the hatch cannot be easily opened from outside the vehicle, increasing the risk of injury.

Blue Bird and SMI have determined that to identify the suspect parts, one would need to check the label on the bottom of the Prolo Hatch for dates between August 1, 2018, and May 20, 2019.

To correct this condition, SMI will provide a parts replacement kit and a Service Repair Procedure, free of charge, on how the repair must be conducted by the servicing agent.  Parts for this recall are currently available.  Parts and Labor Reimbursement for this campaign may be requested through SMI in any one of the three avenues, as outlined below:

Visit the web https://busandrail.safefleet.net/resources/technical–support/

• • Click on Recall Forms
  • 19E042 – Prolo Hatches
• Via e-mail warranty@safefleet.net o Indicate the quantity of Prolo Hatch Handle Service Kits required and provide the following information for each vehicle
  • Company Name
  • Contact Name
  • Contact Phone Number
  • Contact E-mail Address
  • Shipping Address (no Post Office Boxes)
  • Vehicle Manufacturer
  • Blue Bird Body Number
  • VIN Number
  • Hatch Part Number(s)
  • Hatch Build Date
• Phone
  • SMI Customer Service 1-800-951-7867

If SMI does not provide service repair kits, you may contact Blue Bird Body Company Recall Administration at 478-822-2242.

Upon completion of the recall remedy, SMI requests that the Dealer, Service Agent, or Customer file a claim with SMI through warranty@safefleet.net or through the contact information above.  SMI will reimburse at a flat rate of $25.00 for each remedied hatch.  SMI will notify Blue Bird Campaigns Administration of the completion of the recall.

If Blue Bird’s records indicate bus(es) subject to this recall were delivered in your service area, a list of affected bus(es) will be enclosed.  The bus(es) will be identified by Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet.

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

If the modifications directed by this notification were performed on your bus prior to the receipt of this recall notification, submit a copy of the work order/invoice to warranty@safefleet.net   Reimbursements will be made in accordance with the requirements of the National Highway Transportation Safety Act, Title 49 Code of Federal Regulations, Parts 573 and 577.

 

If Blue Bird Body Company should fail to or is unable to remedy this condition without charge to you, you may contact:

ADMINISTRATOR
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
1200 NEW JERSEY AVENUE, SE
WASHINGTON, D.C. 20590

Or, you may call The National Highway Traffic Safety Administration toll free at: 1-888-327-4236    TTY 1-800-424-9153 or go to: http:/www.safercar.gov

 

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R19AF

 

IMPORTANT SAFETY RECALL NOTICE

NHTSA Recall Number:   19V-526 (School Bus)
NHTSA Recall Number:   19V-524 (Non-School Bus)

 

DATE: August 21, 2019

TO: U.S. DEALERS

SUBJECT: RECALL R19AF, Safe Fleet Prolo Roof Hatch Handle

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

This important safety recall notice applies to your buses identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the attached yellow cover sheet.

Blue Bird Body Company and Specialty Manufacturing, Incorporated (SMI) are recalling certain model year 2018 and 2020 Vision School Buses manufactured from September 7, 2018, through July 10, 2019; certain model year 2018-2020 All American School Buses manufactured from September 10, 2018, through June 30, 2019; certain Vision 2020 Non-School Buses manufactured from November 15, 2018, through May 31, 2019; and a 2020 All American Non-School Bus manufactured on November 1, 2018.

On the subject buses, Blue Bird and Specialty Manufacturing, Incorporated (SMI) have determined that some Prolo Hatches may contain defects (voids/porosity) in the outside release handle that have resulted from the casting process.  Excess voids and porosity may create failure points in the handle that can lead to breakage under reasonable use.  Failure of the external release handle will prevent the hatch release mechanism from being actuated from outside the vehicle.  The hatch can still be opened from the outside by venting the hatch and actuating the inside release handle, however, this operation is not intuitive and not detailed in the required instructions located on the hatch.  Failure of the external release handle does not prevent actuation of the release mechanism from inside the vehicle.  Blue Bird and SMI have determined these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 217, Bus Emergency Exits and Window Retention and Release.  If the roof hatch external handle breaks, in the event of an emergency, the hatch cannot be easily opened from outside the vehicle, increasing the risk of injury.

Blue Bird and SMI have determined that to identify the suspect parts, one would need to check the label on the bottom of the Prolo Hatch for dates between August 1, 2018, and May 20, 2019.

To correct this condition, SMI will provide a parts replacement kit and a Service Repair Procedure, free of charge, on how the repair must be conducted by the servicing agent.  Parts for this recall are currently available.  Parts and Labor Reimbursement for this campaign may be requested through SMI in any one of the three avenues, as outlined below:

• Visit the web https://busandrail.safefleet.net/resources/technical–support/
  • Click on Recall Forms
  • 19E042 – Prolo Hatches
• Via e-mail warranty@safefleet.net o Indicate the quantity of Prolo Hatch Handle Service Kits required and provide the following information for each vehicle
  • Company Name
  • Contact Name
  • Contact Phone Number
  • Contact E-mail Address
  • Shipping Address (no Post Office Boxes)
  • Vehicle Manufacturer
  • Blue Bird Body Number
  • VIN Number
  • Hatch Part Number(s)
  • Hatch Build Date
• Phone
  • SMI Customer Service 1-800-951-7867

If SMI does not provide service repair kits, you may contact Blue Bird Body Company Recall Administration at 478-822-2242.

Upon completion of the recall remedy, SMI requests that the Dealer, Service Agent, or Customer file a claim with SMI through warranty@safefleet.net or through the contact information above.  SMI will reimburse at a flat rate of $25.00 for each remedied hatch.  SMI will notify Blue Bird Campaigns Administration of the completion of the recall.

If Blue Bird’s records indicate bus(es) subject to this recall were delivered in your service area, a list of affected bus(es) will be enclosed.  The bus(es) will be identified by Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet.  Dealers should verify correct owners and assure that complete mailing and shipping addresses are provided for each listed owner.

It is the dealer’s responsibility to verify that the correct owner name, address, and telephone number is provided for each listed vehicle.  Any corrections or updates should be made in ClaimsCenter.  Addresses that cannot be updated should be forwarded to the Recall Administrator.

If you have in your possession or have sold a bus that was purchased from another Dealer that may be affected by this recall, please notify me at 478-822-2242 or lisa.hancock@blue-bird.com

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

 Dealers are reminded of their responsibilities under Section 154 of The National Traffic and Motor Vehicle Safety Act of 1991.  Dealers are required to complete modifications on units in their inventory before delivering to the final owner.  Reference Blue Bird Body Company Distributor Memo No. 42-92.

Questions regarding this recall campaign should be directed to me at (478) 822-2242 or lisa.hancock@blue-bird.com

 

Sincerely,

Lisa Hancock
Corporate Recall Administrator
Blue Bird Corporation
402 Blue Bird Blvd, Fort Valley, Georgia 31030
Phone 478.822.2242
lisa.hancock@blue-bird.com

 

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6 Affected Products

Vehicles

BLUE BIRD	ALL AMERICAN	2018-2020
BLUE BIRD	VISION	2018-2020

 

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11 Associated Documents

Recall Quarterly Report #3, 2020-1

RCLQRT-19V526-2783.PDF 211.336KB

 

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ISSUED Renotification Notice

RCRN-19V526-0683.pdf 739.205KB

 

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Recall 573 Report- Amendment 1

RCLRPT-19V526-9398.PDF 214.469KB

 

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Recall Acknowledgement

RCAK-19V526-5330.pdf 244.955KB

 

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Defect Notice 573 Report

RCLRPT-19V526-5883.PDF 214.469KB

 

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Recall Quarterly Report #1, 2019-3

RCLQRT-19V526-6986.PDF 211.149KB

 

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Recall Quarterly Report #2, 2019-4

RCLQRT-19V526-9502.PDF 211.253KB

 

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Recall 573 Report- Amendment 2

RCLRPT-19V526-3177.PDF 214.47KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-19V526-2468.pdf 659.943KB

 

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Remedy Instructions and TSB

RCRIT-19V526-2919.pdf 684.333KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-19V526-9143.pdf 627.496KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V526&docType=RCL

 

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Last update on 2025-04-15 / Affiliate links / Images from Amazon Product Advertising API

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