Brake Light Switch may Keep Brake Lights On – 2013-2020 Blue Bird Vision School Buses

November 6, 2019 NHTSA CAMPAIGN NUMBER: 19V795000

Brake Light Switch may Keep Brake Lights on

Improperly functioning brake lights could confuse following motorists and fail to warn them that the bus may be stopping, increasing the risk of a crash.

 

NHTSA Campaign Number: 19V795

Manufacturer Blue Bird Body Company

Components EXTERIOR LIGHTING

Potential Number of Units Affected 16,402

 

Summary

Blue Bird Body Company (Blue Bird) is recalling certain 2013-2020 Vision school buses equipped with Ford engines. The brake light switch mounting bracket may have caused the brake light switch to be incorrectly adjusted at installation and/or the brake light switch mounting bracket may deform when the driver allows the brake pedal to return forcibly. An incorrectly adjusted brake light switch or deformed brake light switch mounting bracket may cause the brake lights to illuminate continuously.

 

Remedy

Blue Bird distributed owners an interim notification on December 10, 2019. Dealers will install a new, redesigned brake light switch mounting bracket along with a new brake light switch, free of charge. The recall began March 6, 2020. Owners may contact Blue Bird customer service at 1-478-822-2242. Blue Bird’s number for this recall is S19AI-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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R19AI

 

IMPORTANT SAFETY RECALL NOTICE

NHTSA Recall Number:   19V-795 School Bus

NHTSA Recall Number:   19V-796 Non-School Bus

 

DATE:	March 6, 2020
SUBJECT:	RECALL R19AI – Service Brake Switch Bracket Deformation on Driver Control Module (Hydraulic Brake)

 

 

Dear Blue Bird Owner:                

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 coversheet and return to Blue Bird in the enclosed pink postage prepaid envelope.

 

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

 

This notification applies only to hydraulic brake buses previously affected by this campaign.  If your VIN population also includes air brake buses, an additional letter will be provided, when parts are available.

 

Blue Bird Body Company has performed additional data analysis and testing on the hydraulic brake switch assembly. It was determined that hydraulic brake switch brackets are not susceptible to the failure mode present in air brake applications.  Therefore, Blue Bird is removing model year 2013 to 2020 hydraulic brake Blue Bird Vision School Buses equipped with Ford engines manufactured from January 24, 2012 through May 24, 2019 and model year 2016 to 2020 Blue Bird Vision Non-school Buses manufactured from September 24, 2014 through February 7, 2019.  All submitted requests for hydraulic parts will be removed from the parts orders received.

 

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

 

Please contact your local Blue Bird Dealer with any questions regarding this recall campaign. 

 

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

 

BLUE BIRD BODY COMPANY

3920 Arkwright Road, Suite 200, Macon, GA  31210 – (478) 825-2021

 

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R19AI

 

IMPORTANT SAFETY RECALL NOTICE

(Interim Notice)

NHTSA Recall Number:   19V-795 School Bus

NHTSA Recall Number:   19V-796 Non-School Bus

 

DATE:	December 10, 2019
SUBJECT:	RECALL R19AI – Service Brake Switch Bracket Deformation on Driver Control Module

 

 

Dear Blue Bird Owner:

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 coversheet and return to Blue Bird in the enclosed pink postage prepaid envelope.

 

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

 

Blue Bird Body Company is voluntarily recalling certain model year 2013 to 2020 Blue Bird Vision School Buses equipped with Ford engines manufactured from January 10, 2012 through August 7, 2019 and certain model year 2013 to 2020 Blue Bird Vision Non-school Buses manufactured from November 20, 2012 through March 28, 2019. On the subject buses, the potential exists that the brake switch mounting bracket could deform, as a result of a rapid return of the brake pedal to the non-braking position. This is most commonly a result of the driver’s foot slipping off of the brake pedal while the pedal is fully depressed. A deformed brake switch mounting bracket could result in continuously illuminated brake lights and a brake warning light in the vehicle instrument cluster. There is no direct safety consequence because the brake system continues to function normally. However, local operating procedures may require the bus to stop immediately due to the illuminated brake warning light in the vehicle’s instrument cluster. The transfer of passengers to another bus in potentially hazardous conditions could increase the risk of injury.

 

To correct this potential issue, Blue Bird will provide the owners with instructions on how to remove the existing brake switch mounting bracket and install the provided redesigned mounting bracket. Blue Bird will also provide a new brake switch as part of the kit to ensure that the switch has the correct set point after the new brake switch mounting bracket is installed. Parts for this recall are anticipated to be available in March, 2020.  Campaigns Administration will notify you again, when the parts are available.  When requesting parts, please specify air or hydraulic. 

 

Blue Bird will reimburse the labor cost of the repairs related to this recall at no cost to the vehicle owner. The standard repair time (SRT) to accomplish these repairs in accordance with the recall installation procedure is 0.6 hours per bus.

 

Parts to complete Recall R19AI can be obtained from Blue Bird Recall Administration via e-mail at campaignparts@blue-bird.com or by returning the yellow cover sheet to Blue Bird in the pink self-addressed, postage prepaid envelope to receive parts at no charge. You should retain a copy of the reply sheet for your records.

 

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, attach a copy of the work order/invoice. Mail the documents in the pink self-addressed postage prepaid envelope included with the pink reply sheet to Blue Bird for warranty consideration. Reimbursements willbe made in accordance with the requirements of the National Highway Transportation Safety Act, Title 49 Code of Federal Regulations, Parts 573 and 577.

 

Please contact your local Blue Bird Dealer with any questions regarding this recall campaign. 

 

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

 

BLUE BIRD BODY COMPANY

3920 Arkwright Road, Suite 200, Macon, GA  31210 – (478) 825-2021

 

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R19AI

 

IMPORTANT SAFETY RECALL NOTICE

(Interim Notice)

NHTSA Recall Number:   19V-795 School Bus

NHTSA Recall Number:   19V-796 Non-School Bus

 

DATE:	December 10, 2019
TO:	U.S. DEALERS
SUBJECT:	RECALL R19AI – Service Brake Switch Bracket Deformation on Driver Control Module

 

                       

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 is voluntarily recalling certain model year 2013 to 2020 Blue Bird Vision School Buses equipped with Ford engines manufactured from January 10, 2012 through August 7, 2019 and certain model year 2013 to 2020 Blue Bird Vision Non-school Buses manufactured from November 20, 2012 through March 28, 2019. On the subject buses, the potential exists that the brake switch mounting bracket could deform, as a result of a rapid return of the brake pedal to the non-braking position. This is most commonly a result of the driver’s foot slipping off of the brake pedal while the pedal is fully depressed. A deformed brake switch mounting bracket could result in continuously illuminated brake lights and a brake warning light in the vehicle instrument cluster. There is no direct safety consequence because the brake system continues to function normally. However, local operating procedures may require the bus to stop immediately due to the illuminated brake warning light in the vehicle’s instrument cluster. The transfer of passengers to another bus in potentially hazardous conditions could increase the risk of injury.

 

To correct this potential issue, Blue Bird will provide the affected Dealers and owners with instructions on how to remove the existing brake switch mounting bracket and install the provided redesigned mounting bracket.  Blue Bird will also provide a new brake switch as part of the kit to ensure that the switch has the correct set point after the new brake switch mounting bracket is installed.  Parts for this recall are anticipated to be available in March, 2020.  Campaigns Administration will notify you again, when the parts are available.  When requesting parts, please specify air or hydraulic. 

 

Blue Bird will reimburse the labor cost of the repairs related to this recall at no cost to you the Dealer or to the vehicle owner. The standard repair time (SRT) to accomplish these repairs in accordance with the recall installation procedure is 0.6 hours per bus.

 

Parts to complete Recall R19AI can be obtained from Blue Bird Recall Administration via e-mail at campaignparts@blue-bird.com or by returning the yellow cover sheet to Blue Bird in the pink self-addressed, postage prepaid envelope to receive parts at no charge. You should retain a copy of the reply sheet for your records.

 

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.

 

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.

 

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 Lisa Hancock at 478-822-2242 or lisa.hancock@blue-bird.com Questions regarding this recall campaign should be directed to Lisa Hancock, as well.

 

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

 

BLUE BIRD BODY COMPANY

3920 Arkwright Road, Suite 200, Macon, GA  31210 – (478) 825-2021

 

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Chronology :

November 2012 – Blue Bird released recall 12V538 to update the brake switch mounting bracket on the initial 452 buses equipped with the Ford brake switch. At the time of this recall, very limited usage experience had been obtained and so in the absence of field data and in an abundance of caution, the decision was made to improve the brake light switch bracket to the mounting bracket design that was utilized through April 2019.

February 2019 – Based on a NHTSA inquiry, Blue Bird initiated a detailed analysis of the Ford brake switch mounting bracket warranty claims and service reports. Blue Bird has received four reports related to deformed brake switch mounting brackets. During this analysis, Blue Bird determined that the Ford brake switch warranty claims and service records could be related to potentially bent mounting brackets. The initial installation of a new Ford brake switch into an in-service bus would result in a new zero position for the brake switch which could correct for any mounting bracket deformation.

April 2019 – Blue Bird implemented a Bendix redesigned mounting bracket assembly into production as a continuing product improvement.

May 2019 – Blue Bird requested that Bendix develop a redesigned mounting bracket for fielded units.

June 2019 – Bendix provide preliminary information on a redesigned mounting bracket for fielded units.

October 2019 – Blue Bird confirmed that a deformed brake switch mounting bracket could result in a brake warning light in the vehicle instrument cluster.

November 2019 – Blue Bird initiated a recall campaign out of an abundance of caution given that the possibility exists that a school bus driver may be required to pull the vehicle over immediately to an unsafe location based on an illuminated brake warning light in the vehicle instrument cluster.

UPDATE: Additional chronology attached as a separate Miscellaneous Document

 

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19V-795 and 19V-796 Updated Chronology

 

December 2019:

Blue Bird performed additional data analysis on the brake switch part usage rates. It was determined that there was a significant difference in the usage rate when comparing the air brake buses to the hydraulic brake buses.

 

December 2019 through January 2020:

Blue Bird conducted additional testing on the hydraulic brake configuration.  This testing confirmed that hydraulic brake switch brackets are not susceptible to the failure mode present in air brake applications.

 

February 2020:

Blue Bird received government approval for the removal of the hydraulic brake buses from this campaign.

 

February 2020:

Blue Bird reduced the campaign population to air brake buses only. As a result, the population for 19V795 is 12,835 air brake school buses. The population for 19V-796 is 114 air brake non-school buses.

 

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8 Affected Products

Vehicle

MAKE	MODEL	YEAR
BLUE BIRD	VISION	2013-2020

 

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14 Associated Documents

Recall 573 Report- Amendment 1

RCLRPT-19V795-4299.PDF 214.155KB

 

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Defect Notice 573 Report

RCLRPT-19V795-6666.PDF 214.155KB

 

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Recall Acknowledgement

RCAK-19V795-7079.pdf 245.549KB

 

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Miscellaneous Document-Supplemental Chronology

RMISC-19V795-1523.pdf 220.01KB

 

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Recall 573 Report- Amendment 6

RCLRPT-19V795-3409.PDF 214.456KB

 

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Recall 573 Report- Amendment 7

RCLRPT-19V795-4428.PDF 214.456KB

 

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Recall Quarterly Report #1, 2020-1

RCLQRT-19V795-2919.PDF 211.134KB

 

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Recall Quarterly Report #2, 2020-2

RCLQRT-19V795-1289.PDF 211.24KB

 

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Owner Notification Letter(Part 577)

RCONL-19V795-7004.pdf 534.293KB

 

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Recall 573 Report-Amendment 5

RCLRPT-19V795-8597.PDF 214.361KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-19V795-1191.pdf 578.912KB

 

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Recall 573 Report- Amendment 2

RCLRPT-19V795-4676.PDF 214.155KB

 

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ISSUED Interim Owner Notification Letter(Part 577)

RIONL-19V795-3391.pdf 545.248KB

 

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Recall Quarterly Report #3, 2020-3

RCLQRT-19V795-8963.PDF 211.322KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V795&docType=RCL

 

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Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API

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