RecallMyCar

Blue Bird Express 4500 Recalls & Complaints by Model Year

NHTSA lists 6 safety recalls and 0 owner complaints across 4 model years of the Blue Bird Express 4500 (2004–2007).

6
safety recalls, all years
0
owner complaints, all years
2004
year with most recalls

Pick your Blue Bird Express 4500 model year

Model yearRecallsComplaints
2007 Blue Bird Express 450020
2006 Blue Bird Express 450030
2005 Blue Bird Express 450010
2004 Blue Bird Express 450040

All Blue Bird Express 4500 recalls (6)

Every NHTSA safety campaign that lists a Blue Bird Express 4500, 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. Tie rod assembly (steering)

    NHTSA 08V259000 Reported 33 vehicles potentially affected BLUE BIRD BODY COMPANY

    Blue bird is recalling 33 my 2006-2007 express 4500 motor coaches equipped with mac tie rod assemblies that did not meet design specification. As a result, the left and/or right tie rod assembly may fracture at high mileage.

    Remedy: Dealers will replace the left and right hand tie rod assemblies with a redesigned tie rod assembly free of charge. The recall began on july 11, 2008. Owners may contact blue bird at 478-822-2242.

    Model years: 2006, 2007

  3. Tie rod assembly (steering)

    NHTSA 07V540000 Reported 12 vehicles potentially affected BLUE BIRD BODY COMPANY

    On certain motor coaches, the castle nuts on the tie rod ends and relay rod studs in the independent suspension assemblies are loose and/or not tightened to specifications. Low and/or no torque on a nut can result in excessive slack in the steering system, thereby allowing the tapered joint to move and subsequently shear the cotter pin.

    Remedy: Blue bird is working with arvin-meritor to repair these coaches (please see 07e094). The recall began on november 19, 2007. Owners may contact blue bird at 1-478-822-2242.

    Model years: 2006

  4. 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

  5. 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

  6. 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: 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.