2004 Blue Bird ALL American Recalls
NHTSA lists 15 recall campaigns for the 2004 Blue Bird ALL American. A recall applies only to vehicles built within the affected range, so check your own VIN at nhtsa.gov/recalls. Repairs for recalls are free at a franchised dealer.
- SeatsCovers: Blue Bird ALL American 2004–2010, Vision 2004–2010, Conventional 2004–2008
Reported issue: Blue bird is recalling certain model year 2004 through 2010 all american, vision, micro bird, and conventional school buses manufactured between january 30, 2003 and may 7, 2009. Incorrect offset leg barrier pads or 2/3 seat back pads may have been installed. Buses with incorrect pads installed fail to conform to the requirements of federal motor vehicle safety standard no. 222, "school bus passenger seating and…
Possible consequence: In the event of a crash, there is an increased risk of injury to the seat occupant(s).
Remedy: Blue bird will notify owners and the buses will be repaired free of charge. The safety recall began on september 18, 2009. Owners may contact blue bird at 1-478-822-2242.
- Electrical system › IgnitionCovers: Blue Bird ALL American 2003–2010
Reported issue: Blue bird is recalling 2,203 model year 2003 through 2010 all american rear engine school buses equipped with optional plug style vandal locks manufactured from july 16, 2003 through april 10, 2009. The plug style vandal lock is not wired to inhibit the starter at the ignition switch when the vandal lock is in the locked position. These buses fail to conform to the requirements of federal motor vehicle safety…
Possible consequence: The vehicles can be started and driven even when an owner may think they cannot.
Remedy: Blue bird will notify owners and repair the buses free of charge. The safety recall began on june 25, 2009. Owner may contact blue bird at 1-478-422-2242.
- Structure › Body › Roof and pillarsCovers: Blue Bird ALL American 2004–2009, Vision 2005–2009
Reported issue: Blue bird is recalling 23,464 my 2005 through 2009 all american and vision school and transit model buses manufactured from january 22, 2004, and march 28, 2008, and my 2004 through 2007 all american school buses and conventional model school buses manufactured from march 6, 2003, through june 16, 2006. The rivet pattern may be incorrect in sections of the rear roof sheet joint that attaches to the rear roof cap…
Possible consequence: In the event of a crash, these panels may separate exposing the occupants to increased risk of injury.
Remedy: Blue bird will notify owners and inspect and repair the buses by adding additional rivets. The recall began on september 18, 2008. Owners may contact blue bird at 478-822-2242.
- Engine and engine cooling › Engine › DieselCovers: Blue Bird ALL American 2004–2007, Xcel 102 2006–2007
Reported issue: Blue bird is recalling 607 my 2004-2007 all american rear engine school buses and my 2006-2007 xcel 102 commercial series transit buses equipped with cummins isc engines. The high pressure fuel line may crack, allowing high pressure diesel fuel into the engine compartment.
Possible consequence: This condition creates the potential for a risk of fire in the engine compartment should the atomized diesel fuel vapor contact an ignition source.
Remedy: Owners will be advised to contact their cummins dealers to have the repair work performed as soon as possible. The recall began on february 28, 2008. Owners may contact blue bird at 1-478-822-2242.
- Electrical system › 12v/24v/48v batteryCovers: Blue Bird ALL American 2001–2006, TC2000 2001–2005, Vision 2004–2006
Reported issue: Certain 2001 through 2006 my blue bird all american, tc2000, and vision transit school buses manufactured between january 5, 2001, and july 15, 2005. These buses are equipped with a battery disconnect switch that has connections that may be loose on the battery switch studs creating the potential for the bus to shut down while in operation.
Possible consequence: Should the bus shut down while in operation, a vehicle crash could occur.
Remedy: Blue bird will notify its owners and instruct them on how to repair the switch. The recall began on october 19 , 2005. Owners may contact blue bird at 478-822-2242.
- Other › School bus stop arm assemblyCovers: Blue Bird ALL American 2002–2006, Conventional 2002–2006, Mini Bird 2002–2006 +2 more
Reported issue: Certain school buses originally sold in or currently registered in the following states: alaska, colorado, connecticut, delaware, idaho, illinois, indiana, iowa, kansas, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, montana, nebraska, nevada, new hampshire, new jersey, new mexico, new york, north dakota, ohio, oregon, pennsylvania, rhode island, south dakota, tennessee, utah, vermont…
Possible consequence: Should the stop arm not perform properly, a child or pedestrian may be endangered by passing vehicles should the motorist not stop at the correct location.
Remedy: Blue bird will notify its customers and replace the original switch with a switch pack that is not sensitive to extreme cold weather and will inspect to ensure the microswitch heater wiring is properly connected free of charge. The recall began on august 12, 2005. Owners may contact blue bird at 478-822-2242.
- Other › School bus stop arm assemblyCovers: Blue Bird ALL American 2002–2006, Conventional 2002–2006, Mini Bird 2002–2006 +2 more
Reported issue: Certain blue bird 2002 through 2006 my all american, conventional, minibird, microbird, vision, and tc2000 school buses originally sold in or currently registered in states other than the following states: alaska, colorado, connecticut, delaware, idaho, illinois, indiana, iowa, kansas, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, montana, nebraska, nevada, new hampshire, new jersey, new…
Possible consequence: Should the stop arm not perform properly, a child or pedestrian may be endangered by passing motorists should the motorist not stop at the correct location.
Remedy: Blue bird will notify all its customers of this campaign. For those buses operated in or near any of the states listed above, blue bird is encouraging the bus owners to obtain the replacement switch. For those buses operated in the warmer states, blue bird will replace the switch upon owner request. For those…
- Vehicle speed controlCovers: Blue Bird ALL American 2001–2005, Commercial 2001–2004
Reported issue: Certain 2001 through 2005 all american, commercial series, and q-bus school and transit buses equipped with john deere 8.1 cng engines. The subject buses equipped with the john deere engines may surge inappropriately due to erractic operation of the air throttle if the engine is taken from full to zero load.
Possible consequence: Unexpected engine surge could result in a vehicle crash, possibly resulting in personal injury.
Remedy: John deere will notify blue bird's customers and repair the engines free of charge. Customers are being instructed to contact john deere at 1-800-jd-engine.
- Engine and engine coolingCovers: Blue Bird ALL American 2002–2005, Conventional 2003–2006, Commercial 2004
Reported issue: Certain 2002-2006 my blue bird all american school and transit buses, conventional school buses, and commercial series transit buses manufactured between december 21, 2002, and february 24, 2005. These buses are equipped with webasto coolant heaters, model dbw 2010, assembled with webasto burner tubes, p/n 303046/26533a manufactured between november 2002 and february 2005. The stainless steel burner tube is made…
Possible consequence: Should the burner tube fail, the coolant heater could overheat, possibly resulting in a fire.
Remedy: Blue bird will notify its customers and replace the burner tubes free of charge. The recall began on march 31, 2005. Owners may contact blue bird at 478-822-2242.
- Equipment adaptive/mobilityCovers: Blue Bird ALL American 2004–2005, Commercial 1999–2004, Conventional 2001–2004 +2 more
Reported issue: Certain blue bird 1999-2005 all american, tc/2000, micro bird, vision, conventional, and commercial series school buses equipped with sure-loc wheelchair securement systems and manufactured between february 17, 1999, and august 13, 2004. Certain sure-lok wheelchair tie-down securement assemblies p/n 8625-13. The sprocket teeth of the retractor assembly may be out of alignment causing the load pawl not to fully seat…
Possible consequence: In the event of a vehicle crash, the wheelchair may not be adequately secured possibly resulting in injuries.
Remedy: Blue bird will notify its customers and replace the defective part free of charge. The recall began september 21, 2004. Owners who take their buses to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact at blue bird at 478-822-2242.
- Seat beltsCovers: Blue Bird ALL American 2004–2005
Reported issue: School and transit buses equipped with driver's 3-point seat belts with incorrect fasteners.
Possible consequence: In the event of a vehicle crash, the shoulder strap can fail, and the driver could be seriously injured.
Remedy: Blue bird will notify its customers to make an appointment with their blue bird distributor to have the driver's 3-point seat belt upper attaching fasteners replaced free of charge. Owner notification is expected to begin june 8, 2004. Owners who take their vehicles to an authorized dealer on an agreed upon service…
- Seat belts › Front › AnchorageCovers: Blue Bird ALL American 2001–2004
Reported issue: On certain rear engine (a3re) school buses, the type and location of the fasteners used to retain the seat belt in the last row of seats does not conform to blue bird engineering specifications.
Possible consequence: This installation may not adequately retain seat belts in the event of a severe crash.
Remedy: Blue bird will provide its distributors and owners the parts and instructions to install the correct fasteners free of charge. Owner notification is expected to begin november 20, 2003. Owners who do not receive the parts and installation instructions within a reasonable time should contact blue bird at 1-478-822-2242.
- Structure › BodyCovers: Blue Bird ALL American 1999–2004, TC2000 1991–2000
Reported issue: Certain school buses fail to comply with the requirements of federal motor vehicle safety standard no. 221, "school bus body joint strength." one or more of the bolts attaching the driver's platform to the floor structure was omitted.
Possible consequence: The rear of the driver's platform may not be properly retained in the event of a crash which could increase the risk of injury or death to passengers.
Remedy: Blue bird will notify its customers and inspect and repair the affected units. Owner notification began on november 20, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact blue bird at 478-822-2242.
- SeatsCovers: Blue Bird ALL American 2001–2004, TC2000 2001–2004, Conventional 2001–2004
Reported issue: On certain school buses equipped with optional seat belts or seat belt "ready" seats, some belts were installed with only two bolts rather than the required three (3) bolts.
Possible consequence: These seats could detach from the wall side attachment points in the event of a vehicle crash, increasing the risk of injury to the seat occupant.
Remedy: Blue bird will furnish to distributors and owners, parts and instructions necessary to install the missing bolt free of charge. Owner notification is expected to on november 3, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a…
- Service brakes, hydraulic › Foundation components › Hoses, lines/piping, and fittingsCovers: Blue Bird ALL American 2003–2004, TC2000 2003–2004, Commercial 2003–2004
Reported issue: On certain front engine school and transit buses equipped with hydraulic brakes, the rear hydraulic brake hose could contact the frame rail and abrade, allowing brake fluid leakage.
Possible consequence: If this occurs, vehicle braking could be affected, increasing the risk of a crash.
Remedy: Dealers will inspect the rear brake hose to frame rail clearance and reposition the brake hose clamps at the axle to ensure adequate clearance. Any chafed brake hoses will be replaced. Owner notification began december 12, 2002. Owners who take their vehicles to an authorized dealer and do not receive the free remedy…
NHTSA investigations
- PE05028School bus stallsClosed · May 25, 2005
← All problems reported for the 2004 Blue Bird ALL American
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 31, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.