Fire Risk
About 1,000 transit buses are being recalled by Motor Coach Industries, Inc. (MCI), the National Highway Traffic Safety Administration announced on Tuesday, November 19, 2009. The vehicles involved are equipped with a Caterpillar C13 engine and 50DN alternator. The alternator’s cable could come loose from a clamp, which may cause chafing to the cable, possibly damaging the cable wires. This could cause a fire. The recall includes 2005-2008 D4000 models, 2005-2009 D4500 models, and 2005-2009 D4505 models. MCI will alert owners and replace the alternator cable’s clamp for free.

Steering Problem
Champion Bus is recalling 14 MY 2007-2008 M1235 and RE CTS buses built on Freightliner chassis. The fasteners that attach the steering arm or tie rod arms to the spindle may be over or under-tightened. Incorrectly tightened steering arm fasteners may fatigue and fracture which could cause a crash without warning. Champion Bus is working with Freightliner to repair these vehicles.

Possible Fall
Eldorado is recalling 210 MY 2006-2007 Aero Elite, Aerotech, Aerolite, and Transtech buses equipped with Braun platform lifts for failing to conform to the requirements of Federal Motor Vehicle Safety Standard No. 404, “Platform Lift Installations in Motor Vehicles.” The threshold warning systems of the wheelchair lifts do not conform to the threshold warning signal. Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured. Braun will correct the wheelchair lift.

Possible Problem with Platform Lift
Girardin is recalling 13 MY 2007-2008 MB IV school and commercial buses, manufactured between November and December 2007, equipped with Ricon wheelchair lifts, Series 5500, manufactured from April 1, 2005 to October 9, 2007. The threshold warning system may not detect the presence of a wheelchair or mobility aid user in a certain spot within the defined threshold area. These lifts do not comply with Federal Motor Vehicle Safety Standard No. 404, “Platform Lift Installations in Motor Vehicles.” The user of the lift could be injured should the lift move unintentionally. Girardin will notify their owners and instruct them to contact Ricon for a free repair. The recall is expected to begin during April 2008.

Possible Separation of Tag Axle From the Coach
MCI is recalling 542 MY 2000-2004 G4100 and G4500 coaches. Certain reworked tag axle arm assemblies had been identified with new cracks forming. Some of the tag axle arm assemblies that had previously been repaired during recall 03V411 or 06V458 may have been repaired with unidentified micro-fractures and/or insufficient weld penetration. If the tag axle swing arm cracks and remains undetected, the cracks can spread and potentially result in a partial or total separation of the tag axle assembly from the coach, increasing the risk of a crash. Dealers will re-inspect and if cracks are identified or incorrect welds in the previously repaired areas, both right and left tag arm assemblies will be replaced. If no problems are identified, dealers will reinstall the existing tag axle arm assemblies with new hardware.

Possible Loss of Steering Control
Millennium Transit is recalling 23 MY 2006 R80THN transit buses. The steering miter box bracket is mounted on a structural beam below the driver and holds the miter gear which connects the steering column to the steering shaft and steering gear. Should there be a failure of the welds holding this bracket together, the result would be a loss of steering or control of the vehicle increasing the risk of a crash. Dealers will ship replacement part brackets along with installation instructions. The recall is expected to begin during April 2008.

Fire Hazard
New Flyer is recalling 431 MY 1996-2001 D60HF diesel transit buses equipped with a rooftop air conditioning evaporator. The evaporator drain lines make contact with components (ballast assemblies) within the interior lighting panel below the drain line port. This can result in either damage to the drain line, which introduces moisture into the lighting panel, or restriction of the line which results in a back-up and overflow of moisture through the fresh air return vent and back into the lighting panel. Moisture in sufficient quantities within the lighting panel may result in a shorting of the electrical components and a vehicle fire. New Flyer will incorporate an elbow fitting into the drain line where it enters the lighting panel from the roof which will promote clearance between the line and the ballast assembly. The recall is expected to begin during March 2008.

Brake Defect and Possible Roll Away
Champion Bus is recalling 20 MY 2007-2008 M1235 buses built on Freightliner chassis and equipped with Bendix SR-7 spring brake modulating valves. The internal rubber check valve may leak causing a delay in the application of the spring brakes to park the vehicle after the operator pulls the dash valve button. This could cause a delay or failure in applying the parking brakes which could result in a vehicle roll away, increasing the risk of a crash. Champion Bus is working with Freightliner and Bendix to repair these vehicles (please see 07V302 and 07E037). Bendix will provide a check valve repair kit for the affected SR-7 spring brake modulating valve free of charge.

Possible Stall
MCI is recalling 24 MY 2008 D4500, D4505, and D4000ISTV coaches equipped with TRW steering gears, Model TAS85. These steering gears contain potentially defective sector shafts with an incorrect gear tooth which may interfere with the rack-piston teeth, resulting in a sticking or binding condition. This condition has the potential to cause the steering gear to stall and restrict the steering turning angle of the vehicle which could result in a vehicle crash. MCI is working with TRW to replace the defective steering gear (please see 07E101). The recall is expected to begin during March 2008. This recall was the subject of an Equipment Query, EA08-002, conducted by the Office of Defects Investigation.

Steering Gear Defect
Champion Bus is recalling 14 MY 2008 3035RE transit buses built on Freightliner chassis and equipped with ZF model 8018 steering gears. These gears may have been assembled with the incorrect recirculating ball spacer. This could potentially allow the recirculation balls to escape from the recirculation ball circuit resulting in a loss of steering. The operator may notice higher required steering wheel inputs, or the need for more steering wheel adjustments while driving in a straight line in combination with metallic cracking noises prior to a loss of steering. Loss of steering could result in a bus crash.

Possible Injury to Person in Wheelchair
Goshen is recalling 90 MY 2006-2007 GC II buses built on General Motors 560 chassis and equipped with an Intermotive Gateway 401 module interlock harness. These buses have been found to exhibit extreme voltage spikes during engine cranking. These extreme spikes can damage the diode in the harness near the shift lock solenoid connector. If the diode fails in the shorted condition, the Gateway 401 module can be damaged. If this occurs, the shift lock solenoid may not engage. If this lock does not engage, the vehicle will have the ability to move while the wheelchair lift is deployed which may result in personal injury.

Fire Risk
Eldorado National – California (ENC) is recalling 106 MY 2004-2007 AXESS, E-Z Rider II and Transmark RE rear engine buses built with Cummins ISL or ISC diesel engines and equipped with the CM850 fuel system. The engine high pressure fuel lines from the engine high pressure pump to the engine fuel rail are prone to failure. The fuel line failures have been determined to be caused by prolonged vibration. Failure typically occurs at or under the fuel line fitting attachments. Failure of the fuel line introduces high pressure atomized diesel fuel into the engine compartment. Fuel into the engine compartment creates a risk of fire due to possible ignition when the fuel vapor comes in contact with hot surfaces. ENC will work with Cummins to install a support bracket on the high pressure fuel lines free of charge. The recall is expected to begin during March 2008.

Explosion Risk
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. This condition creates the potential for a risk of fire in the engine compartment should the atomized diesel fuel vapor contact an ignition source. Owners will be advised to contact their Cummins dealers to have the repair work performed as soon as possible. The recall is expected to begin on or about March 18, 2008.

Engine May Shut Down or Start on Fire
International is recalling 34,993 MY 2007-2008 CECB, CESB, FECB, FESB, HC, RECD, RESB, 1300, 3200, 4300, 7300, 7500, CXT, MY 2007 3300, 8500, RXT, MY 2006-2007 4400, MY 2006-2007 4400, and MY 2006-2008 7400 school buses, transit buses and heavy duty truck/tractors manufactured between June 1, 2006 and June 28, 2007, equipped with International DT466 or DT570 engines. The base plate of the engine oil cooler may crack allowing pressurized oil to leak into the engine compartment. This condition may cause either engine shut down without warning, or in extreme cases, possible engine fire which can lead to property damage, personal injury, or death. International will notify owners and repair the vehicles free of charge.

Possible Loss of Control
NABI is recalling 92 MY 2006 60BRT articulated 60′ transit buses. The main castings may prematurely fail. If the casting fractures, loss of vehicle control could occur increasing the risk of a crash. Dealers will replace the main castings. The recall is expected to begin during February 2008.

Possible Failure of Air Brake System
Gillig is recalling 249 MY 2006-2007 Phantom and Low Floor transit buses equipped with Graham-White air dryers. The air dryer timer modules may allow sufficient quantities of moisture to enter and affect the operation of the vehicle air brake system. Failure of the air brake system due to moisture could result in a crash. Gillig, in conjunction with Graham-White, will replace the air dryer timer module on the affected vehicles. The recall is expected to begin during February 2008.

Exposed Lift Doorway and Risk of Fall
International is recalling 1,027 MY 2006-2007 BE, CE, FE, and RE school buses and MY 2006-2007 CE and FE commercial buses for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 404, “Platform Lift Installations in Motor Vehicles.” A passenger can approach the exposed lift doorway without the audible alarm alerting them of their proximity to the threshold. Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured.

Defective Seat Belt
Collins is recalling 296 MY 2005-2006 Bantam, Grand Bantam, Super Bantam, and Omni school buses for failing to comply with all the requirements of Federal Motor Vehicle Safety Standard No. 209, “Seat Belt Assemblies,” and No. 210, “Seat Belt Assembly Anchorages.” The web of the belt rubs up against the retractor’s metal sleeve causing friction and abrasion, and over time, may fray the belt. In the event of a vehicle crash, the seat occupant may not be properly restrained possibly resulting in injury. Collins will notify owners and replace the seat belt. The recall is expected to begin during February 2008.

Steering Problem
Glaval is recalling 62 MY 2007-2008 Synergy transit buses built on Freightliner XB-R chassis and equipped with ZF Model 8018 steering gears. These gears may have been assembled with the incorrect recirculating ball spacer. This could potentially allow the recirculation balls to escape from the recirculation ball circuit resulting in a loss of steering. The operator may notice higher required steering wheel inputs, or the need for more steering wheel adjustments while driving in a straight line in combination with metallic cracking noises prior to a loss of steering. Loss of steering could result in a vehicle crash. Glaval is working with Freightliner and ZF to replace the steering gear (please see 07V343 and 07E049).

Engine Stall
Ford is recalling 1,176,000 MY 1997-2003 F-Super Duty, E-Series and Excursion vehicles equipped with 7.3L diesel engines. The camshaft position sensor located on the engine of the vehicle may function intermittently, possibly resulting in an engine stall. In the event of an engine stall, a crash could result without warning. Dealers will inspect the sensor and replace it with an improved camshaft position sensor. The recall is expected to begin during January 2008.

Possible Fall from Lift
Blue Bird is recalling 451 MY 2006-2007 All American, Conventional, and Micro Bird school buses equipped with Model 900 Series wheelchair lifts manufactured by the Braun Corporation. The threshold warning system may not activate as designed which fails to conform to Federal Motor Vehicle Safety Standard No. 404, “Platform Lift Installations for Motor Vehicles.” Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured. Owners will be notified by Blue Bird instructing them to contact Braun for a free repair. The recall is expected to begin during January 2008.

Possible Passenger Injury
Girardin is recalling 33 MY 2003, 2005, and 2006 MB II and MB IV school and commercial buses on Ford and GM chassis with 6.6L engines equipped with Braun Lift Models NL916, NL917, and NL919. The threshold warning system may not activate as designed which fails to conform to Federal Motor Vehicle Safety Standard No. 404, “Platform Lift Installations for Motor Vehicles.” Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured. Owners will be notified by Girardin instructing them to contact Braun for a free repair. The recall is expected to begin during January 2008.

Lift Defect
Champion Bus is recalling 375 MY 2005-2007 Champion, Challenger, Crusader, CTS, Defender and General Coach Corporal and M1235 buses for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 403, “Platform Lift Systems for Motor Vehicles.” A passenger can approach the exposed lift doorway without the audible alarm alerting them of their proximity to the threshold. Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured. Champion Bus is working with Braun to have the doorway lift fixed (please see 07E094). 07V-567

Possible Exposed Lift Doorway
Eldorado is recalling 25 MY 2006 Transmark, Escort RE, MST and MST II buses equipped with Braun platform lifts for failing to comply with the requirements of Federal Motor Vehicle Safety Standard No. 403, “Platform Lift Systems for Motor Vehicles.” A passenger can approach the exposed lift doorway without the audible alarm alerting them of their proximity to the threshold. Should the threshold warning system fail to operate, the lift user can fall from the vehicle and be seriously injured. Eldorado is working with Braun to have the doorway lift fixed (please see 06E094).

Possible Steering Issue
Farber Specialty Vehicles is recalling 32 MY 2002-2007 specialty vehicles such as bookmobiles, medical, dental, display and command buses built on Freightliner chassis and equipped with ZF Model 8018 steering gears. These gears may have been assembled with the incorrect recirculating ball spacer. This could potentially allow the recirculation balls to escape from the recirculation ball circuit resulting in a loss of steering. The operator may notice higher required steering wheel inputs, or the need for more steering wheel adjustments while driving in a straight line in combination with metallic cracking noises prior to a loss of steering. Loss of steering could result in a vehicle crash. Farber is working with Freightliner and ZF to replace the steering gear (please see 07V343 and 07E049).

Bus Fire Risk
Freightliner is recalling 33,303 MY 2001-2008 Thomas Built FS-56, ER, MVP ER, HDX, and MVP EF school buses equipped with Tyco PC boards and Type II auto reset circuit breakers. Type II auto reset circuit breaker temperatures may exceed the rating of the Tyco PC board causing the boards to melt increasing the risk of a vehicle fire. The manufacturer has not yet provided the agency with a remedy program. The recall is expected to begin on or about February 1, 2008. This campaign supersedes safety recall 06V-136. This recall was the subject of a Preliminary Evaluation, PE07-029, conducted by the Office of Defects Investigation.

Fire Hazard Due to Leaking Oil
International is recalling 10,744 MY 1996-2004 RE commercial and school buses equipped with International T444E V-8 diesel engines. Hose assemblies that supply high pressure oil to the engine’s cylinder heads may deteriorate over time and allow oil to leak or mist the engine compartment. This leaking oil can catch fire possibly resulting in property damage, personal injury or death. International will notify owners and replace the hoses with newly designed, more weather resistant hoses. The recall is expected to begin on or about August 10, 2007.

Possible Loss of Brake Fluid
Freightliner is recalling 431 MY 2006-2007 Thomas Built FS-65 school and shuttle bus chassis equipped with Caterpillar C7 engines and hydraulic brake lines. The front brake lines may have been improperly secured allowing the brake line to contact the engine coolant plumbing components. This could cause a loss of brake fluid and reduced brake performance potentially resulting in a vehicle crash without warning. Freightliner will notify owners and repair the buses. The recall is expected to begin on or about July 20, 2007.

Possible Fuel Spillage during or after Accident
Freightliner is recalling 6,880 MY 2005-2007 Thomas Built Saf-T-Liner C2 school buses. Fasteners used to secure the fuel tube mounting bracket to the bus floor may be missing or improperly installed. Vehicles with missing or improperly installed fuel fill tube mounting bracket fasteners do not comply with the requirements of Federal Motor Vehicle Safety Standard No. 301, “Fuel Systems Integrity.” This could result in fuel spillage during or after a vehicle crash possibly resulting in a fire. Freightliner will notify owners and repair the buses. The recall is expected to begin on August 3, 2007.

Roll Away Risk
Blue Bird is recalling 5,977 MY 2004-2007 Vision school and transit buses equipped with Parker single check valves (SCV) provided by Bendix. The defect exists in the Parker SCV that connects with the supply port of the SR-7 spring brake modulating valve. After prolonged use of the Parker SCV, the valve body retainer may become excessively worn and eventually break apart. Pieces of the Parker SCV can become lodged inside the SR-7 spring brake modulating valve, potentially causing either leakage out of the SR-7 valve or preventing air from properly exhausting from the SR-7 valve. This condition can cause a delay in the application of the spring brakes to park the vehicle after the operator pulls the dash valve button. These conditions can occur without warning, leading to unintended vehicle rollaway, brake drag, or in the case of loss of primary circuit, inability to modulate the spring brakes. Blue Bird will notify owners and provide a free remedy. The manufacturer has not yet provided the agency with a notification schedule.

Fire and Explosion Hazard
Eldorado National – California is recalling 59 MY 1998-2003 Escort RE-A and Transmark RE rear engine buses built with propane tanks. Weld failures are occurring at the point where the connecting tubes meet the tank body. The weld failure may result in propane leakage which could result in an explosion or fire. Eldorado will replace the tank on the affected vehicles. The recall is expected to begin during July 2007.

Rollaway Hazard
Blue Bird is recalling 4,530 MY 2007 and 2008 Vision and All American school and transit buses equipped with Bendix SR-7 spring brake modulating valves. The internal rubber check valve may leak causing a delay in the application of the spring brakes to park the vehicle after the operator pulls the dash valve button. The delayed parking brake application can occur without warning, leading to unintended vehicle rollaway. Blue Bird will notify owners and provide a free remedy. The manufacturer has not yet provided the agency with a notification schedule.

Gusset Problems
Motor Coach is recalling 163 MY 1999-2003 F3500 transit buses. Where the steering arm idler bracket mounting is attached to the underside of the frame, the frame structure can crack and the idler plate can separate. This could lead to loss of steering control and a crash without warning. MCI will add reinforcement gussets in order to reduce the stress where cracking can occur, and will repair the existing components in the affected units as necessary. The recall began on May 15, 2007.

Possible Air Brake System Failure
NABI is recalling 183 MY 2006-2007 40LFW and 60BRT transit buses equipped with Graham White air dryers. The air dryer timer modules may allow sufficient quantities of moisture to enter and affect the operation of the vehicle air brake system. Failure of the air brake system due to moisture could result in a crash. NABI, in conjunction with Graham White, will replace the air dryer timer module on the affected vehicles. The manufacturer has not yet provided an owner notification schedule.

Seat Defect May Cause Passenger to be Thrown during Crash
U.S. Bus is recalling 106 MY 2000-2006 Sturdibus, Sturdivan, and Universe school buses for failing to conform to the requirements of Federal Motor Vehicle Safety Standard No. 210, “Seat Belt Assembly Anchorages.” The wall and floor mounting bolts can pull through the supporting steel in the event of a crash failing to retain the seat, allowing the passenger to be thrown forward causing personal injuries. U.S. Bus will notify owners and repair the buses free of charge. The recall is expected to begin during April 2007.

Side Emergency Door May Not Work
International is recalling 6,184 MY 2004-2007 IC CE, RE, and FE commercial and school buses. The side emergency door holdback mechanism may not be installed in the proper location. This may cause the mechanism to hold the door in the closed position. If the door is held in the closed position, it may not perform its intended emergency function, possibly resulting in personal injury, death or property damage. IC will notify owners and repair the affected buses free of charge. The recall is expected to begin on or about April 6, 2007.

Faulty Wheelchair Lift
Freightliner is recalling 350 MY 2006-2007 Thomas Built Minotour school buses equipped with a wheelchair lift option. Plastic zip ties found around the wheelchair lift interlock switches may prevent the switch from operating, defeating the interlock function allowing the vehicle to be driven with the lift still deployed. Moving the vehicle with the lift deployed could cause injury to bystanders or a crash. Thomas Built dealers will inspect the buses and any plastic ties found on the switches will be removed. The recall is expected to begin during March 2007.

Possible Engine Malfunction
Nova Bus is recalling 900 MY 1994-2002 RTS transit buses equipped with Detroit Diesel Series 50 engines. The electronic control module (ECM) will need to be reprogrammed to activate the exhaust temperature sensor. Engine malfunction could possibly lead to engine and vehicle damage with the potential for a vehicle fire. Nova Bus is working with Detroit Diesel to reprogram the engines (please see 05E050). This recall began on January 26, 2007.

Possible Seat Detachment
U.S. Bus is recalling 38 MY 2003-2006 Sturdibus school buses for failing to comply to the requirements of Federal Motor Vehicle Safety Standard No. 210, “Seat Belt Assembly Anchorages.” In the event of a crash, the seats attached to the floor track can detach possibly resulting in injuries. U.S. Bus will notify owners and repair the buses free of charge. The recall is expected to begin during February or March 2007.

Possible Visibility Problem
Freightliner is recalling 1,441 MY 2006-2007 Thomas Built C2 school buses. The inlet air fitting welded to the base plate was manufactured inconsistently, possibly allowing the fitting to separate. Separation of the inlet fitting will prevent the actuating air from powering the crossing arm so it may not deploy. If the crossing arm does not deploy, the bus driver may not see the students as they cross in front of the bus during pick-up or discharge, presenting a risk to them. Thomas Built will notify owners and repair the buses free of charge. The recall is expected to begin on February 28, 2007.

Wiper Failure Risk
Blue Bird is recalling 882 MY 2007-2008 Vision school buses. Continuous resetting of the circuit breaker when the wiper/washer is operating in the “Wash/Wipe” mode may cause failure in the wiring circuit. This could result in power being applied to ground which could cause the circuit breaker to overheat and fail resulting in a stalled wiper. Failure of the wiper in inclement weather conditions may cause a vehicle crash, possibly resulting in property damage, personal injury, or death. Blue Bird will install a relay in the windshield wiper “Wash/Wipe” circuit. The recall is expected to begin on or about February 28, 2007.

Defective Steering
Blue Bird is recalling 227 MY 2008 Vision school buses. A temporary bolt was used to secure the steering wheel during the manufacturing process. The temporary bolt was to be removed and replaced with a permanent bolt with a lock coating during the final assembly stage. The temporary bolt was not removed and replaced on the subject units, but instead the bolt was reused. Reuse of the attaching screw could allow the steering wheel to loosen during operation which could result in a vehicle crash causing injury or death to occupants. Blue Bird will notify owners and repair the buses by replacing the screw with a new attaching screw. The recall began on December 11, 2006.

Brake Failure Hazard
DaimlerChrysler Commercial Buses is recalling 250 MY 2004-2005 Orion VII buses equipped with Graham White brake air dryer model QBA15. The brake air dryer timer does not function properly. The air entering into the brake system may not have the moisture removed. If not properly drained, small ice crystals may form in the brake system preventing the system operating the brakes properly. The bus may not perform as expected when stopping, increasing the risk of a crash. DaimlerChrysler is working with Graham White to develop a remedy. Owners are being asked to inspect the wet brake air tank for moisture by using a manual drain. Only two customers are involved and have been contacted.

School Bus Recall: Risk of Dragging Student
International is recalling 211 MY 2003-2007 IC CESB and MY 1998 3800 school buses. The handrails were not installed correctly which could allow passenger coat strings or drawstrings to get caught as the passenger exits the bus. Should a passenger get caught while exiting the bus, death or personal injury could occur. IC will notify owners and repair the buses free of charge. The recall is expected to begin on November 17, 2006.