R21BC-NSB – Electronic Stability Control Malfunction – 2022 Blue Bird All American Buses

February 17, 2021 NHTSA CAMPAIGN NUMBER: 21V084000

Electronic Stability Control Malfunction

If the electronic stability control does not function properly, it can increase the risk of a crash or injury.

 

NHTSA Campaign Number: 21V084

Manufacturer Blue Bird Body Company

Components ELECTRONIC STABILITY CONTROL

Potential Number of Units Affected 2

 

Summary

Blue Bird Body Company (Blue Bird) is recalling certain 2022 All American buses equipped with hydraulic brakes and electronic stability control (ESC). The Hydraulic Brake control unit (ECU) may not have been programmed correctly, possibly causing the ESC to malfunction.

 

Remedy

Blue Bird will notify owners, and dealers will inspect the hydraulic brake ECU and repair it as necessary, free of charge. The recall began on April 9, 2021. Owners may contact Blue Bird customer service at 1-478-822-2242. Blue Bird’s number for this recall is R21BC-NSB.

 

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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RECALL

R21BC – Hydraulic Brake Electronic Control Unit (ECU) Programming

Models Affected: Certain MY2021-2022 BBCV and T3FE with Hydraulic Brake and Electronic Stability Control (ESC)

Issue: Certain Blue Bird buses with Hydraulic brakes and Electronic Stability Control (ESC) may not have the ECU programed to vehicle specific parameters

Corrective Action: Replace the ECU modulator assembly with a pre-programmed, VIN specific replacement part

WARNING: Always follow all Federal, State, Local and Shop safety standards and use proper safety equipment, and thoroughly read and understand all instructions before performing these procedures.

Park bus on level surface, apply parking brake, turn off ignition key, and chock wheels.

 

Required hardware/software to perform this repair:

Prior to beginning the repair, ensure you have TOOLBOX PLUS installed along with necessary drivers to properly
connect to and calibrate the vehicle.

1. Laptop with TOOLBOX PLUS software version 13.2 or most recent version

2. A RP1210 communication device supported by the TOOLBOX PLUS tooling software

a. Blue Bird recommended RP1210 communication device: Dearborn DPA-5 USB

 

Reference Documentation and Link:

https://www.wabco-auto.com/americas_en/Get-in-touch/Literature

 

Applicable literature available on WABCO website:

MM1543 SmartTrac Hydraulic ABS (WABCO maintenance manual)

TP19060 TOOLBOX PLUS Software Installation Instructions

MM19047 TOOLBOX PLUS™ Diagnostic Software User Guide

 

Replacement Parts:

As the Hydraulic ABS module is vehicle specific, a replacement module will be provided for each unit with body number identifier on the box and on the module assembly. Once the module assembly is replaced, bleeding the system and calibration of the system is required for completion of the campaign. The modulator assemblies will be shipped to each dealer, there will be no need to order from recall parts or return the original modulator assembly.

 

Modulator Removal:

NOTE: Refer to the WABCO maintenance manual MM1543 and review section 5.1.4 thru 5.2.4 prior to repair.

The manual can be found by clinking on the link above located under “Reference Documentation and Link”.

1. Locate the Hydraulic ABS modulator assembly inside the left-hand frame rail, rear of the transmission (Illustration 1, item 4)

2. Disconnect the negative terminal of the battery

3. Disconnect the chassis wire harness’s electrical connector on the ECU

4. Label each line on the modulator assembly for later installation. Reference Illustration 2, as needed

5. Using a catch pan to collect any brake fluid, remove each line on the modulator assembly, take care not to twist the line.

6. Remove the mounting fasteners securing the modulator assembly to the frame rail and retain (items 1 and 2)

7. Lower and set aside the modulator assembly.

8. Remove the protective lip rubber from the bracket flange and retain (item 3).

 

Modulator Installation:

IMPORTANT: Confirm the body number on the ECU matches the unit being repaired.

1. Place new modulator assembly inside the frame rail, correctly oriented and loosely install the top bolt (1) and washer (2) thru the frame to hold the assembly in place

2. Line up and install the remaining bolts and washers (items 1 and 2), tighten until snug

3. Torque the fasteners to 140 FT-LBS

4. Install protective lip rubber (item 3) previously removed, using black silicone to retain in place

5. Connect the brake lines per Illustration 2, observe torque specifications

 

IMPORTANT: Do not twist the lines when tightening

 

6. Connect the electrical harness to the ECU

7. Connect the negative battery terminal

 

Bleeding Instructions:

1. Reference WABCO manual MM1543, section 5.2.4 for bleeding instructions

 

Calibration Instructions:

1. Reference WABCO manual MM1543, section 5.3 for calibration instructions

 

Connecting to vehicle:

Connect the RP1210 compliant device to the vehicle J1939 diagnostic connector (Photo 1)

If the vehicle is Cummins powered, the use of BB tool adapter #10049528 is REQUIRED

If the vehicle is Ford powered, no tool adapter is necessary.

 

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R21BC

 

IMPORTANT SAFETY RECALL NOTICE

 

NHTSA Recall Number:   21V-083 School Bus

NHTSA Recall Number:  21V-084 Non-School Bus

 

DATE: April 14, 2021

 

SUBJECT: R21BC:  Hydraulic Brake Electronic Control Unit (ECU) Programming  

 

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 pink 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.

 

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 the following:

• Certain model year 2021 through 2022 Blue Bird Vision School Buses
  • manufactured from December 12, 2019 through November 11, 2020
• Certain model year 2022 Blue Bird All American School Bus
  • manufactured from October 28, 2020 through November 4, 2020
• Certain model year 2022 Blue Bird All American Non-School Buses
  • manufactured from August 17, 2020 through August 24, 2020

 

On the subject buses, it has been determined that certain Blue Bird buses with hydraulic brakes and Electronic Stability Control (ESC) did not have the ECU programmed to vehicle specific parameters.  This can cause the ESC to not be able to function as designed and may not work in an optimized condition based on vehicle parameters.  The affected buses will have the ECU modulator assembly part number identified and repaired accordingly.  Blue Bird evaluated the risk to motor vehicle safety related to this issue and determined that, in the event of an accident, there is a potential for injury to the occupant if the ESC does not operate, as designed.  Blue Bird shall conduct a voluntary safety recall to correct this potential issue.

 

Corrective Action: 

Please contact your local Blue Bird dealer to arrange to have the Recall performed and to ensure that parts are available at the dealership. To locate an authorized dealer, search online at www.blue–bird.com/find–a–dealer  The Recall will take approximately four hours and will be performed at no charge to you.

 

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 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.

 

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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R21BC

 

IMPORTANT SAFETY RECALL NOTICE

 

NHTSA Recall Number:   21V-083 School Bus

NHTSA Recall Number:  21V-084 Non-School Bus

DATE:	April 14, 2021
TO:	U.S. DEALERS
SUBJECT:	R21BC:  Hydraulic Brake Electronic Control Unit (ECU) Programming

 

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 the following:

• Certain model year 2021 through 2022 Blue Bird Vision School Buses
  • manufactured from December 12, 2019 through November 11, 2020
• Certain model year 2022 Blue Bird All American School Bus
  • manufactured from October 28, 2020 through November 4, 2020
• Certain model year 2022 Blue Bird All American Non-School Buses
  • manufactured from August 17, 2020 through August 24, 2020

 

On the subject buses, it has been determined that certain Blue Bird buses with hydraulic brakes and Electronic Stability Control (ESC) did not have the ECU programmed to vehicle specific parameters.  This can cause the ESC to not be able to function as designed and may not work in an optimized condition based on vehicle parameters.  The affected buses will have the ECU modulator assembly part number identified and repaired accordingly.  Blue Bird evaluated the risk to motor vehicle safety related to this issue and determined that, in the event of an accident, there is a potential for injury to the occupant if the ESC does not operate, as designed.  Blue Bird shall conduct a voluntary safety recall to correct this potential issue.

 

Corrective Action:

To correct this condition, replace the ECU modulator assembly with a pre-programmed, VIN/Body Number specific replacement part.  The replacement module will be provided for each unit with a body number identifier on the box and on the module assembly.

 

Labor Reimbursement:  

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 R21BC remedy procedure(s) is outlined below.

 

Repair Option and allowable labor time for this campaign:

Repair:

• 4 Hours
• Replace the ECU modulator assembly with a pre-programmed, VIN/Body Number specific replacement part. The replacement module will be provided for each unit with a body number identifier on the box and on the module assembly, per recall instructions.

 

Administering the Recall and Parts:

Parts will be provided to the respective Dealers and are unit specific.  There will be no need to order recall parts or return the original modulator assembly.  Parts to complete Recall R21BC will be available May 3, 2021.  

 

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 [email protected] 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
[email protected]

 

BLUE BIRD BODY COMPANY

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

 

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1 Affected Product

Vehicle

MAKE	MODEL	YEAR
BLUE BIRD	ALL AMERICAN	2022

 

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14 Associated Documents

Recall 573 Report- Amendment 1

RCLRPT-21V084-7970.PDF 214.374KB

 

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Recall Quarterly Report #5, 2022-2

RCLQRT-21V084-4068.PDF 211.574KB

 

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Recall Quarterly Report #1, 2021-2

RCLQRT-21V084-2993.PDF 211.574KB

 

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V084-2380.PDF 211.574KB

 

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Recall Quarterly Report #6, 2022-3

RCLQRT-21V084-2058.PDF 211.574KB

 

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Recall Quarterly Report #2, 2021-3

RCLQRT-21V084-5505.PDF 211.574KB

 

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Recall Quarterly Report #4, 2022-1

RCLQRT-21V084-9244.PDF 211.574KB

 

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Recall Acknowledgement

RCAK-21V084-5426.pdf 645.817KB

 

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Defect Notice 573 Report

RCLRPT-21V084-5449.PDF 214.306KB

 

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Remedy Instructions and TSB

RCRIT-21V084-2318.pdf 969.116KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-21V084-1570.pdf 826.226KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V084-0531.pdf 601.901KB

 

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Recall Quarterly Report #8, 2023-1

RCLQRT-21V084-2338.PDF 211.733KB

 

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Recall Quarterly Report #7, 2022-4

RCLQRT-21V084-0454.PDF 211.733KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V084&docType=RCL

 

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