Blue Bird TC2000 Recalls & Complaints by Model Year
NHTSA lists 64 safety recalls and 38 owner complaints across 19 model years of the Blue Bird TC2000 (1987–2005). The most-complained-about year is 1994.
Pick your Blue Bird TC2000 model year
| Model year | Recalls | Complaints |
|---|---|---|
| 2005 Blue Bird TC2000 | 1 | 0 |
| 2004 Blue Bird TC2000 | 5 | 0 |
| 2003 Blue Bird TC2000 | 6 | 8 |
| 2002 Blue Bird TC2000 | 11 | 0 |
| 2001 Blue Bird TC2000 | 12 | 0 |
| 2000 Blue Bird TC2000 | 12 | 1 |
| 1999 Blue Bird TC2000 | 15 | 5 |
| 1998 Blue Bird TC2000 | 17 | 0 |
| 1997 Blue Bird TC2000 | 8 | 0 |
| 1996 Blue Bird TC2000 | 13 | 3 |
| 1995 Blue Bird TC2000 | 18 | 7 |
| 1994 Blue Bird TC2000 | 14 | 9 |
| 1993 Blue Bird TC2000 | 14 | 2 |
| 1992 Blue Bird TC2000 | 14 | 1 |
| 1991 Blue Bird TC2000 | 12 | 0 |
| 1990 Blue Bird TC2000 | 13 | 1 |
| 1989 Blue Bird TC2000 | 14 | 1 |
| 1988 Blue Bird TC2000 | 11 | 0 |
| 1987 Blue Bird TC2000 | 1 | 0 |
What Blue Bird TC2000 owners complain about
Across all model years, owners have filed 38 complaints with NHTSA. The 1994 model year has the most, with 9.
All Blue Bird TC2000 recalls (64)
Every NHTSA safety campaign that lists a Blue Bird TC2000, most recent first, with the model years each one covers.
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12v/24v/48v battery (electrical system)
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…
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.
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School bus stop arm assembly (other)
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,…
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…
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School bus stop arm assembly (other)
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,…
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…
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Fuel system, diesel
Certain 1998 through 2002 blue bird all american, tc2000 school and transit buses, and commercial series buses equipped with cummins isb diesel engines. The fuel pump could fail to transfer fuel appropriately creating an engine stall condition.
Remedy: Customers will be notified by cummins to bring their vehicles to an authorized dealer to have the fuel lift pump replaced free of charge. For more information, customers may contact cummins at 1-800-diesels.
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Equipment adaptive/mobility
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…
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…
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Body (structure)
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.
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…
Model years: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000
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Seats
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.
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…
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Alternator/generator/regulator (electrical system)
On certain school and transit buses equipped with cummins isb 6 cylinder engines, the lower alternator support brace or mounting hardware can loosen or break which will allow the alternator to drop onto the engine.
Remedy: Cummins will notify customers and replace the upper and lower alternator support brackets free of charge. Owners who take their vehicle to an authorized dealer on an agreed upon service date and do not receive the free…
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Hoses, lines/piping, and fittings (service brakes)
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.
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…
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Alternator/generator/regulator (electrical system)
On certain front engine school and transit buses equipped with blue bird option 40177 cummins isb engine, the alternator power cables may not be routed properly from the alternator output to the starter motor.
Remedy: Dealers will add a loom and reroute the electrical power cable from alternator output to starting motor. The alternator power cable will be replaced if abrasions are found. Owner notification is expected to begin on or…
Model years: 1998
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Retractor (seat belts)
On certain school and transit buses equipped with passenger seat belts with retractors, the cover halves for the retractable portion of the belt can separate completely and release the seat belt connector. If this occurs, one of the load bearing pins in the connector could separate from the connector and render the seat belt unusable.…
Remedy: Owners will be provided a snap-on "over-cover" to prevent the seat belt cover from separating. Owner notification is expected to begin on or about september 27, 2002. Owners who do not receive the free remedy within a…
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Labels (equipment)
Certain transit buses fail to comply with requirements of federal motor vehicle standard no. 101, "controls and displays." this standard requires specific labeling for "engine start" and "engine stop." the wording of the labels on these vehicles do not meet the requirements of the standard.
Remedy: Owners will be provided with new decals and installation instructions. Owner notification began august 29, 2002. Owners who do not receive the free label and installation instructions within a reasonable time should…
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Manual transmission (power train)
On certain school and transit buses equipped with allison 2000 series transmissions, the "range inhibited" indicator light on the dash was improperly installed and does not function.
Remedy: Distributors and owners will be instructed to remove the dash and activate the indicator "range inhibited" light according to instructions provided. Owner notification began august 16, 2002. Owners who take their…
Model years: 2002
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Seats
Certain school buses equipped with optional high back seats with 9" split sash, pushout windows fail to comply with the requirements of federal motor vehicle safety standard no. 217, "bus emergency exits and window retention and release." the affected units have seats located incorrectly with respect to the pushout window openings.
Remedy: Dealers will relocate the seats and pushout windows. Owner notification began july 24, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy…
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Suspension
Vehicle description: school buses equipped with hendrickson rear air suspension. Inadequate tightening of the 5/8" bolts on the rear air suspension hanger bolts and on rear axle torque arm axle seat studs.
Remedy: Dealers will replace the 5/8" grade 8-hanger bolts. In addition, axle spring seat fasteners will be checked for proper tightness and, if needed, tightened to specifications. Owner notification began january 18, 2002.…
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Chamber (service brakes)
Vehicle description: school and transit buses. Insufficient torque on the arvin-meritor air brake chamber mounting nuts can allow the nuts to loosen over time.
Remedy: Dealers will inspect the torque values on each brake chamber nut and tighten to specifications. Owner notification began november 16, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon…
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Electrical system: wiring
Vehicle description: school and transit buses equipped with rear mounted engines. The 12-volt power supply cable(s) may be chaffed by hoses, harnesses, frame components, or clamps.
Remedy: Dealers will remove and inspect the 12-volt power cable(s) from the battery to the starter and, if necessary, will replace the cables. Owner notification began july 30, 2001. Owners who take their vehicles to an…
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Tie rod assembly (steering)
Vehicle description: school and transit buses and motor home chassis equipped with tie rod assemblies manufactured by trw. The suspect tie rods contain 24-dl model ball sockets. Certain of the tie rod ball-socket bearings have a below-specification case depth and/or hardness, which can lead to premature wear of the socket.
Remedy: Dealers will replace the defective ball sockets and/or drag links. Owner notification began march 30, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the…
Model years: 1999
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Slack adjusters (service brakes)
Vehicle description: school and transit buses equipped with a combination spicer j230 rear axle, spring suspension, and crewson brunner automatic slack adjusters. The crewson brunner slack adjuster contacts a u-bolt mounting bracket when a combination of the listed components are installed. The combination does not allow for full…
Remedy: Dealers will install modified u-bolt brackets that will provide the needed clearance. Owner notification began march 15, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and…
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Antilock (service brakes)
Vehicle description: transit and school buses equipped with meritor wabco phase 1, d-version antilock brake system (ABS), fail to comply to the requirements of FMVSS no. 105, "hydraulic and electric brake systems." an internal diagnostic system in the ABS may not detect an extreme wheel speed sensor air gap. Such a condition could…
Remedy: The ABS ECU will be removed and replaced or the ECU will be reprogrammed.
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Pressure relief devices (fuel system)
Vehicle description: school and transit buses equipped with compressed natural gas engines (cng). The original pressure relief devices may vent unexpectedly.
Remedy: Dealers will replace the pressure relief devices.
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Antilock (service brakes)
Vehicle description: school and transit buses built with bendix air ABS with an ec-17 1030r electronic control unit (ECU), there have been reports of unwanted ABS activation at low speeds caused by 1) chafed ABS wheel speed sensor wires on rotating parts or 2) a damaged component at the wheel end that generates a certain type of erratic…
Remedy: Dealers will replace the ABS ECU.
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Body (structure)
Vehicle description: school buses. These buses fail to meet the 60 percent joint strength requirements of FMVSS no. 221, "school bus body joint strength."
Remedy: Owners will be contacted and advised to inspect each roof joint. Owners will install repair rivets in each joint found to have insufficient quantity of rivets in each examined 8 inch section.
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Accelerator pedal (vehicle speed control)
Vehicle description: school and transit buses equipped with electronic engines and felsted electronic accelerator pedals. The return springs can break on the accelerator pedals that are equipped with stainless steel or electroplated music wire return springs.
Remedy: Replacement accelerator pedals equipped with return springs manufactured of music wire with one additional coil on each spring and with an organic coating, eliminating electroplating will be installed.
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Foot control/valve (service brakes)
Vehicle description: school and transit buses equipped with bendix air brakes. Bendix changed the internal design of the qr1c relay valve by adding a hole in the internal diaphragm. When the hole in the diaphragm aligns with the hole in the valve body, the brake application time increases.
Remedy: Dealers will replace the diaphragms with holes with solid diaphragms for the qr1c valves.
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Hoses, lines/piping, and fittings (service brakes)
Vehicle description: school and transit buses equipped with bendix ABS anti-lock braking system. The primary and secondary brake treadle valve air lines were installed incorrectly at the bendix r12dc relay valve.
Remedy: Dealers will correct the air line plumbing at the bendix r12dc relay valve.
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Suspension: front
Vehicle description: school buses. There is a shimmy in the front end of the bus.
Remedy: Owners will be provided with an axle damper kit and installation instructions.
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Electrical system: wiring
Vehicle description: school buses equipped with cummins isb engines. Electrical power cables may not have been routed properly from the alternator output to the starting motor.
Remedy: Dealers will add loom and reroute the electrical power cable from the alternator output to staring motor. Any cables found with abrasions will be replaced.
Model years: 1998
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Seats
Vehicle description: school buses. The wall side attaching bolts for some of the passenger seats may have been installed too close to the edge of the seat ledge and in the wrong attaching hole resulting in weakening of the seat ledge at the attachment points.
Remedy: Blue bird will furnish to distributors and owners, parts and instructions necessary to strengthen the passenger seat attachment at the wall side.
Model years: 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
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Electrical system: front underhood
Vehicle description: school and transit forward and rear engine buses equipped with cummins isb and isc engines. The wiring harness to the combustion air intake grid heater can chafe against the engine and wear through causing an electrical short in the grid heater power supply. The short causes the fusible link to fail.
Remedy: Owners will be advised to replace the original grid heater power supply harness with fusible links with a new grid heater power supply harness equipped with fuses. In addition, a clamp will be added to support the…
Model years: 1998
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Hoses, lines/piping, and fittings (fuel system)
Vehicle description: rear engine school buses equipped with option 04888 dedicated compressed natural gas (cng) fuel package. The 24" long stainless steel braided fuel hoses can leak at the hose end fittings.
Remedy: Dealers will replace these hoses with conductive thermoplastic hoses.
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Interior lighting
Vehicle description: school and transit buses. The parking brake indicator light can illuminate without the parking brake being set.
Remedy: Dealers will add a diode to the stop light circuit to prevent illumination of the parking brake indicator unless the parking brake has been set.
Model years: 1998
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Tank assembly (fuel system)
Vehicle description: front and rear engine school buses equipped with 60 gallon side mounted fuel tank barriers. These buses do not comply with the requirements of FMVSS no. 301, "fuel system integrity."
Remedy: Blue bird will ship instructions and modification kits to the owners of these buses.
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998
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Power train
Oversized rotors were installed in the powertrain drive motors in these buses.
Remedy: Northrup-grumman will perform the modification to these powertrain drive motors.
Model years: 1996
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Hose, piping, and connections (steering)
The power steering hose with a crimped end fitting was improperly manufactured.
Remedy: Owners are requested to inspect the power steering hose for the suspect hoses (identifiable by date code) and replace hoses as necessary.
Model years: 1996
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Hoses, lines/piping, and fittings (service brakes)
Interference between the hydraulic brake hoses or bleeder valves and the "reyco" air suspension components can occur causing failure of one of the hydraulic fittings.
Model years: 1995
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Seats
Vehicle description: school buses equipped with bostrom driver's seat model f222 or bostrum "routemaster" seat. Blue bird option 2821 or 2824. The seat pedestals are fatigue cracking adjacent to the weld which secures the pedestal's upper plate to the upper, telescoping portion of the adjustable column support.
Remedy: Dealers will repair these pedestals with a newly designed pedestal bracket kit.
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Body (structure)
Passenger's clothing can unknowingly become caught in the forward handrails at bus doors when exiting the bus.
Remedy: Owners will be directed to remove all forward handrails. Provisions will be made for those owners operating in states which mandate a forward handrail that a replacement handrail will be provided.
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
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Chamber (service brakes)
Air suspension torque arm can come in contact with the air brake chamber mounting bracket resulting in broken s-cam mounting bracket.
Remedy: Dealers will modify vehicles to incorporate an axle seat spacer and replace the cam shaft and cam shaft bracket with a longer cam shaft and cam shaft bracket on both right and left rear brake assemblies to provide…
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Fuses and circuit breakers (electrical system)
The wrong circuit breaker was installed in the electrical panel which could cause an interruption of the 8-light warning system.
Remedy: Owners will be notified to check and replace as necessary the circuit breakers. Owners can also have these circuit breakers checked and replaced at an authorized dealer.
Model years: 1995
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Body (structure)
These buses are equipped with an entrance door handrail off set brace attached to the interior wall and the handrail. The attachment point at the wall is incorrectly positioned permitting the entrapment of the "connecticut nut/string test device" between the upper edge of the brace and the lower edge of the seat ledge. Passenger's…
Remedy: Dealers will inspect and relocate the bracket as necessary. Owners can inspect and relocate the bracket is so desired.
Model years: 1995
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Glass, side/rear (visibility)
These vehicles could have a latch which scrapes an aluminum trim piece increasing the force required to open. This does not comply with FMVSS no. 217, "bus window retention and release."
Remedy: Dealers will install a new cam lock plate.
Model years: 1995
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Body (structure)
An improper mix of adhesive was applied to the interior side panel joints resulting in the buses failing to conform to the joint strength requirements of federal motor vehicle safety standard no. 221, "school bus body joint strength.":
Remedy: Dealers will inspect and repair with correct adhesive if the sealer was not cured properly.
Model years: 1995
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Body (structure)
The floor line handrail bracket can expand during use and create an opening which could entrap coat strings, etc. And other articles of clothing.
Remedy: Dealers will replace the flat split floor line bracket with a round tubular bracket.
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Frame and members (structure)
These units are equipped with a counter weight assembly made up of 300 pounds of 1/4" plate steel welded together and bolted between the frame rails in the rear overhang just forward of the rear bumper. Some of the welds have broken due to insufficient welds, corrosion, or ice expansion.
Remedy: Dealers will install a mechanical retaining device which clamps the plates together and fastened with threaded fasteners. Bus owners will have the option of repairing their own vehicles.
Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
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Body (structure)
Passengers clothing can unknowingly become caught in the handrails at bus doors when exiting the bus.
Remedy: Dealers will install a set screw to the metal clamp which retains the intermediate handrail. A high impact molded plastic "clam shell" will be placed over each end of the intermediate handrail completely covering the…
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Knee bolster (air bags)
The aisle side styrofoam knee pads on the subject barriers are 11" wide and not 14.5" as required by FMVSS no. 222, "school bus passenger seating and crash protection."
Remedy: Dealers will replace the incorrect pad with the correct 14.5" knee pad.
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Linkages (steering)
Quench cracks occurred in the pitman arm pinch bolt during the bolt manufacturing process, causing a weakness in these bolts.
Remedy: Blue bird will provide replacement bolts for all affected units.
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Hoses, lines/piping, and fittings (service brakes)
Air brake supply lines are reversed at the brake treadle valve. This can cause the modulated spring brake feature on the rear axle brake to be inoperable. In the event the rear brake supply reservoir were lost, this could result in loss of brakes without proper function of the modulated spring brake action of the rear brake axle to stop…
Remedy: Vehicle owners will be instructed to swap supply lines at the treadle valve to obtain the correct plumbing, and will be reimbursed for labor expenses.
Model years: 1994
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Chamber (service brakes)
An incorrect size brake chamber may have been installed on the front and/or rear brake assemblies which could affect the brake balance and stopping distance.
Remedy: Bus owners will be provided with instructions to inspect their vehicles and provide blue bird with certain information. Blue bird will review the information and, where needed, will forward replacement brake chambers…
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Hose, piping, and connections (steering)
The hydraulic hoses which interconnect with the hydraulic pump, hydraulic radiator fan motor and power steering gear have an undersized wire mesh core which results in an improper hose end crimp. The improper crimp can cause a leak, emptying the power steering hydraulic fluid reservoir, resulting in loss of power steering assist.
Remedy: Owners are being asked to inspect hose for the date code 3-1q93 which is embossed on the hose cover every 18 inches. Replacement hoses will be provided. Owners can handle the repair themselves or have a blue bird…
Model years: 1993
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Latch (latches/locks/linkages)
A weld in the door lock assembly used on rear and/or side emergency doors can be overstressed and break. When this occurs, a closed door cannot be opened, or if open it cannot be latched.
Remedy: Replace the defective door locks.
Model years: 1991
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Service brakes, air
The front brake air lines are incorrectly routed through the pressure protection valve at the auxiliary wet tank. This results in lack of air pressure to the front brakes when the air pressure in the auxiliary wet tank drops below 65 p.s.i., resulting in inoperable front brakes.
Remedy: Correctly reroute the brake lines.
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Body (structure)
Passengers clothing can unknowingly become caught in the handrails at bus doors when exiting the bus.
Remedy: Replace or reposition the handrails to stop clothing from becoming caught.
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Latch (latches/locks/linkages)
The electric vandal lock center plunger can tap the control lock pin, of the outward opening door, which causes the door lock to become disengaged.
Remedy: Modify the vandal door locks with blue bird supplied kits.
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Fuses and circuit breakers (electrical system)
A 150 amp circuit breaker, option 4362, has been wired in parallel with a standard equipment circuit, thereby not providing the required protection.
Remedy: The standard equipment circuit must be removed.
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Slack adjusters (service brakes)
The front air brake automatic slack adjuster contacts the steering arm preventing proper brake adjustment.
Remedy: Replace the front air brake chambers with chambers that have longer push rods.
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Hoses, lines/piping, and fittings (service brakes)
The hydraulic brake hose mounted on the rear axle may rub against the left frame rail.
Remedy: Install a bracket at rear axle to provide additional clearance between the brake hose and the frame rail.
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Switch (exterior lighting)
Undersized crimp on wire from headlight switch to dimmer switch creates electrical resistance and can cause a short in the headlight wiring system.
Remedy: Replace dimmer switch with new 14 gauge wire with properly crimped connections.
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Steering wheel/handle bar (steering)
Lock pins in steering wheel and hub assembly my shear off, allowing steering wheel to spin.
Remedy: Repair using a positive locking method.
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Vacuum (service brakes)
Bendix hydraulic brake booster may malfunction under certain combinations of fluid temperature and brake pedal force.
Remedy: Replace hydraulic brake booster.
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Tank assembly (fuel system)
The diesel fuel filter separator is located too close to the chassis frame cross member which could deform and dislodge the bowl of the separator in an accident.
Remedy: Relocate fuel filter - separator to eliminate interference with crossmember in any crash.
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Drum (service brakes)
Front axle assemblies may contain cracked brake drums due to improper fit between the wheel hubs and the brake drums.
Remedy: Replace defective brake drums.
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Steering wheel/handle bar (steering)
Loose retaining nut on steering wheel could cause the steering wheel to feel loose.
Remedy: Torque retaining nut to specification and apply locktite.
Model years: 1989
Other Blue Bird models
- All American52 complaints
- School Bus33 complaints
- Vision23 complaints
- Conventional14 complaints
- Blue Bird13 complaints
- Wanderlodge M450 Lxi9 complaints
- All American School Bus8 complaints
- Buses8 complaints
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.