What Blue Bird ALL American owners have reported to NHTSA, the service bulletins the manufacturer sent dealers, and any federal defect investigations, by model year. See Blue Bird ALL American safety recalls or check your VIN.
Complaints owners filed with NHTSA, by the model year of the vehicle. A high count can also mean a popular year, so compare it with how many were sold.
| Year | Complaints | Crashes | Fires | Injured | Deaths | TSBs |
|---|---|---|---|---|---|---|
| 2025 | 0 | 0 | 0 | 0 | 0 | 1 |
| 2024 | 0 | 0 | 0 | 0 | 0 | 1 |
| 2023 | 2 | 0 | 0 | 0 | 0 | 3 |
| 2022 | 2 | 0 | 1 | 0 | 0 | 7 |
| 2021 | 0 | 0 | 0 | 0 | 0 | 6 |
| 2020 | 4 | 0 | 0 | 0 | 0 | 16 |
| 2019 | 2 | 0 | 0 | 0 | 0 | 17 |
| 2018 | 0 | 0 | 0 | 0 | 0 | 17 |
| 2017 | 0 | 0 | 0 | 0 | 0 | 46 |
| 2016 | 1 | 0 | 0 | 0 | 0 | 34 |
| 2015 | 3 | 0 | 0 | 0 | 0 | 25 |
| 2014 | 0 | 0 | 0 | 0 | 0 | 17 |
| 2013 | 1 | 0 | 0 | 0 | 0 | 19 |
| 2012 | 0 | 0 | 0 | 0 | 0 | 24 |
| 2011 | 0 | 0 | 0 | 0 | 0 | 24 |
| 2010 | 1 | 0 | 0 | 0 | 0 | 22 |
The vehicle systems named most often in Blue Bird ALL American complaints (one complaint can name several).
In the owners’ own words, as filed with NHTSA. Unverified reports; NHTSA removes personal details before publishing.
The contact called about a 2020 Blue Bird BB Conventional. The contact was a bus driver for the Coweta School District and stated that while at the diesel fuel pump, diesel spilled out of the spout. The contact stated that the failure occurred after the vehicle was fueled and while closing the fuel cap. The contact stated that approximately two gallons of diesel spilled out of the spout. The contact stated that the vehicle was parked, and the following day, the contact found a diesel fuel spill on the ground. The contact stated that approximately four gallons of diesel were lost. No warning lights were illuminated. A contact notified the fleet mechanic about the issue. The mechanic informed …
The contact owns a 2023 Blue Bird Conventional Bus. The contact stated that while driving at 65 MPH, the instrument panel unexpectedly rebooted. The contact also stated that while attempting to make a turn, the bus experienced a reduction in power. There was no warning light illuminated. The vehicle was taken to a dealer, but was not diagnosed or repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 61,000.
The contact's employer owns a 2022 Blue Bird Conventional. The contact stated that upon further inspection, it was noticed that the battery arms were fracturing at the frame of the bolts. No warning lights were illuminated. The contact related the failure to NHTSA Campaign: 17V100000 (Structure); however, the VIN was not included. The local dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 101,928.
The complaint was submitted on behalf of the Buna ISD School System. The contact was a certified mechanic for the Buna ISD School System. The contact inspected the 2023 Blue Bird School/Transit Bus and noticed that all the seat knobs were fractured. In addition, the contact inspected the fleet of buses with the same failure. The manufacturer was not made aware of the failure. The failure mileage was unknown.
Bluebird Next Gen seats continuously break. The seat bottoms break under the weight of a high school aged kid. If the child is sitting in the seat when it breaks it could injure the child. The seat backs also break regularly.
I am writing to bring to your attention several persistent issues we have encountered with the Blue Bird student seating in our buses. The seat backs, constructed from a black mesh material welded at all four corners and secured with a top bar, have repeatedly failed. We have observed that nearly all of our seats have broken seat backs, necessitating multiple repairs at Central States of Lexington. Despite these efforts, we continue to find broken seat frames. This is particularly concerning as, in the event of an accident, these seats would not adequately provide the necessary compartmentalization for student safety. We are in the process of replacing the seat frames in the buses that are …
I am writing to bring to your attention several persistent issues we have encountered with the Blue Bird student seating in our buses. The seat backs, constructed from a black mesh material welded at all four corners and secured with a top bar, have repeatedly failed. We have observed that nearly all of our seats have broken seat backs, necessitating multiple repairs at Central States of Lexington. Despite these efforts, we continue to find broken seat frames. This is particularly concerning as, in the event of an accident, these seats would not adequately provide the necessary compartmentalization for student safety. We are in the process of replacing the seat frames in the buses that are …
I am writing to bring to your attention several persistent issues we have encountered with the Blue Bird student seating in our buses. The seat backs, constructed from a black mesh material welded at all four corners and secured with a top bar, have repeatedly failed. We have observed that nearly all of our seats have broken seat backs, necessitating multiple repairs at Central States of Lexington. Despite these efforts, we continue to find broken seat frames. This is particularly concerning as, in the event of an accident, these seats would not adequately provide the necessary compartmentalization for student safety. We are in the process of replacing the seat frames in the buses that are …
Repair instructions and other communications the manufacturer sent dealers about known issues. A TSB is not a recall, and the repair is usually free only while the car is under warranty; ask your dealer for the bulletin number.
Blue Bird has identified a software issue affecting the Neutral-at-Stop feature. A software update is required in-person at an authorized Allison Transmission Dealer.
A motor high temperature error can display on the instrument cluster when the OEM coolant valve in the closed position restricting coolant flow through the high voltage propulsion motor.
SM2203: EV Recommended Starting Procedure This Service Memorandum is to announce the proper starting procedure to be followed for all Cummins EV powered units. The sequence is required due to multiple electronic modules required to wake up and start communicating over the CAN (Controller Area Network) on EV Power Train ProductâÂÂ.
SM2022 EV Maintenance and Service Documentation This Service Memorandum is to announce information on Cummins Power Electric buses now available at Quickserve Online. Dealer must have access to Quickserve to obtain these service maintenance and repair procedures.
Cummins recently issued Temporary Repair Practice (TRP2484) for certain vehicles with DEF sensor failures in which DEF sensor replacement parts are not available. This provides a temporary ECM calibration that inhibits engine warning messages for communication errors with the DEF sensor allowing continued operation without engine derate. Regulators are allowing for this temporary calibration to be loaded in the engine ECM by a Cummins authorized repair location if the DEF sensor fails. This temporary calibration does not repair the failure therefore a final repair must be performed and the
The intent of Service Update SU2105 is to provide service notification of a running product improvement part change to the relay used for diesel exhaust fluid (DEF) line heaters. The new DEF line heater relay will be "Diode Suppressed". The new relay change is being made to improve circuit fault diagnostic capabilties. This change implements two new diode suppressed relay part numbers based on bus model application. The new relays are easily distinguishable by color. They have a yellow high temp tape wrap. Models Affected: Vision (BBCV), All American, and TX4 (T3FE, T3RE), with EPA/CARB ce
The intent of Service Update SU2104 is to provide a quick reference document of âÂÂRequired Dealer Service Support Softwareâ for servicing, a current production model Blue Bird Bus. The list includes standard OEM bus and truck service software such as; Cummins INSITEî, and Allison DOCî, and it also includes unique service software applications that are required to fully service a Blue Bird bus such as; AMETEKî, ACTIAî, and MODINEî. These software applications provide troubleshooting support and software update capabilities. This document is intended to be a âÂÂliving
The intent of Service Update SU2103 is to announce a new Shaw Development Technical Bulletin. The Technical Bulletin is intended to guide Shaw Development customers in troubleshooting fault codes related to the DEF tank assembly on Cummins engine equipment. This document is intended to be a âÂÂliving documentâÂÂ, and the details and processes within can/will change as system designs evolve, or other new information comes to light. Access to this Shaw Development Technical Bulletin will be available on the Blue Bird Vantage website.
The intent of Service Update SU2101 is to provide instruction when windshield replacement is required on buses equipped with Blue Bird Factory Installed Mobileye Collision Mitigation Features. Applicable Blue Bird features: 38105-34 âÂÂMOBILEYE,COLLISION MITIGATION,250kBâ USA 38105-35 âÂÂMOBILEYE,COLLISION MITIGATION,500kBâ USA (NEA Only)
This SKU is a DEF Injector. The customer communication requested return of unsold inventory to inspect the sealing. The injector sealing may have an issue which will cause a slow leak. A slow leak of the DEF Injector can lead to crystal formation which can cause aftertreatment related fault codes and ECU driven engine derating.
The intent of Service Memorandum SM1906 is to make Blue Bird dealers aware that Cummins has released a calibration update improvement to reduce occurrence of âÂÂEngine fault codes 3555 and 3556â on Cummins diesel engines with the following base ECM calibrations, "HC80145 thru HC80250 and HB80104 thru HC80195"
Models Affected: 2010 thru 2021 All American Subject: This update provides information on the new surge tank fill necks for All American Instructions: There is a new kit available from Part Sales; 10066291 - Kit, Neck, Surge Tank. This kit is available for use with the All American & TX4 surge tanks. Remove and discard existing neck from tank Install new neck using items in Kit 10066291 Kit, Neck, Surge Tank
NHTSA’s Office of Defects Investigation opens these when complaints point to a possible safety defect. Many end in a recall.
See the attached closing report.
Source: NHTSA Office of Defects Investigation public data (complaints, manufacturer communications, investigations), model years 2010 and later. Had a safety problem? Report it to NHTSA.
In complaints filed with NHTSA for model years 2010–2025, owners most often name: seats, electrical system, service brakes. 16 complaints are on record.
No. A complaint is an unverified report from an owner. A technical service bulletin (TSB) is the manufacturer telling dealers how to fix a known issue; it is not a safety recall and is usually covered only under warranty. A recall is a formal safety action, and its repair is free.
File a vehicle safety complaint at NHTSA.gov. NHTSA reads every report, and patterns of complaints are what open defect investigations and, eventually, recalls.