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Blue Bird Express 4000 Recalls & Complaints by Model Year

NHTSA lists 4 safety recalls and 0 owner complaints across 5 model years of the Blue Bird Express 4000 (2003–2007).

4
safety recalls, all years
0
owner complaints, all years
2004
year with most recalls

Pick your Blue Bird Express 4000 model year

Model yearRecallsComplaints
2007 Blue Bird Express 400010
2006 Blue Bird Express 400010
2005 Blue Bird Express 400010
2004 Blue Bird Express 400040
2003 Blue Bird Express 400010

All Blue Bird Express 4000 recalls (4)

Every NHTSA safety campaign that lists a Blue Bird Express 4000, most recent first, with the model years each one covers.

  1. Electrical system

    NHTSA 13V480000 Reported 393 vehicles potentially affected Blue Bird Body Company

    Blue Bird Body Company (Blue Bird) is recalling certain model year 2004 Ultra LMB, 2003-2006 Ultra LF and 2004-2007 Express commercial buses equipped with Sure Power-brand battery equalizers containing a particular epoxy sealing, aka 'potting', compound. The specific potting compound used in the subject products for insulation was found…

    Remedy: Blue Bird will notify owners, and dealers will replace the equalizers, free of charge. The recall began on December 17, 2013. Owners may contact Blue Bird at 1-478-825-2021. Blue Bird's recall number is R13WN.

    Model years: 2004, 2005, 2006, 2007

  2. Disc (service brakes)

    NHTSA 04V388000 Reported 156 vehicles potentially affected BLUE BIRD BODY COMPANY

    Certain motor coaches, motor homes, commuter coaches, and transit buses equipped with arvin-meritor dx 225 air disc brakes, are experiencing excessive smoke in the wheel area due to overheating of the air disc brake pads.

    Remedy: Arvin-meritor will inspect the brake assemblies to ensure proper set-up and operation. This recall began august 10, 2004. Owners should contact blue bird at 478-822-2242.

    Model years: 2004

  3. Check valve (service brakes)

    NHTSA 04V341000 Reported 48 vehicles potentially affected BLUE BIRD BODY COMPANY

    Certain motor coaches fail to comply with the requirements of federal motor vehicle safety standard no. 121, "air brake systems." these buses were manufactured without the check valve, which protects the front service brake reservoir.

    Remedy: Dealers will add the required check valve to the front air brake service reservoir to insure compliance with FMVSS no. 121. The recall began on july 30, 2004. Owners should contact blue bird at 478-822-2242.

    Model years: 2004

  4. Linkages (steering)

    NHTSA 04V153000 Reported 98 vehicles potentially affected BLUE BIRD BODY COMPANY

    On certain motor homes and transit coaches, incorrect torque application could have been applied to the clamp bolts and the drag link.

    Remedy: Dealers will replace the clamp bolts and and tighten to the required torque. Owner notification began on april 7, 2004. Owners should contact blue bird at 478-822-2242.

    Model years: 2003, 2004

Other Blue Bird models

Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.