Blue Bird Express 4000 recalls
Every NHTSA recall campaign filed since 2000 that names the Blue Bird Express 4000, newest first. Last verified Sep 13, 2026.
Units are totals reported across campaigns mentioning this model — NHTSA does not always break unit counts down by model.
Affected components
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →All campaigns
- Oct 17, 2013Fire risk2004–2007 Blue Bird Express 4000, 2004–2007 Blue Bird Express 4500, 2003–2006 Blue Bird Ultra LF and 1 other model — Electrical System
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 to be capable of conducting electricity after being exposed to heat.
13V480000 · 393 units · Blue Bird Body Company
- Aug 4, 2004Fire risk2004 Blue Bird Express 4000, 2004 Blue Bird Express 4500, 2003–2005 Blue Bird Ultra LF and 1 other model — Service Brakes, Air
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.
04V388000 · 156 units · BLUE BIRD BODY COMPANY
- Jul 19, 2004Crash risk2004 Blue Bird Express 4000, 2004 Blue Bird Express 4500 — Service Brakes, Air
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.
04V341000 · 48 units · BLUE BIRD BODY COMPANY
- Mar 26, 2004Crash risk2003 Blue Bird Express 3500, 2003–2004 Blue Bird Express 4000, 2004 Blue Bird Express 4500 and 1 other model — Steering
ON CERTAIN MOTOR HOMES AND TRANSIT COACHES, INCORRECT TORQUE APPLICATION COULD HAVE BEEN APPLIED TO THE CLAMP BOLTS AND THE DRAG LINK.
04V153000 · 98 units · BLUE BIRD BODY COMPANY