2004 Blue Bird Express 4000, 2004 Blue Bird Express 4500, 2003–2005 Blue Bird Ultra LF and 1 other model Recall: CERTAIN MOTOR COACHES, MOTOR HOMES, COMMUTER COACHES, AND TRANSIT BUSES…
NHTSA campaign 04V388000 · Service Brakes, Air · filed Aug 4, 2004 · verified Sep 14, 2026
The defect
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.
The risk
A POTENTIAL FIRE IN THE WHEEL MAY OCCUR WHICH MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY.
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 →The fix — what to do
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.
BLUE BIRD RECALL NO. R04HW.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Affected vehicles
Related recalls
More Blue Bird Express 4000 recalls
- 2004–2007 Blue Bird Express 4000 and 3 other models — Specific potting compound used in the subject products for…
- 2004 Blue Bird Express 4000 and 1 other model — CERTAIN MOTOR COACHES FAIL TO COMPLY WITH THE REQUIREMENTS…
- 2003 Blue Bird Express 3500 and 3 other models — ON CERTAIN MOTOR HOMES AND TRANSIT COACHES, INCORRECT…
Other campaigns involving Blue Bird vehicles
- 2025–2027 Blue Bird Vision School Bus — Electrical contactor may fail, preventing the controls from…
- 2023–2027 Blue Bird Vision School Bus and 1 other model — 12V power wire on one of the harnesses may become damaged…
- 2023–2027 Blue Bird Vision Transit Bus — 12V power wire on one of the harnesses may become damaged…
All Blue Bird Express 4000 recalls → · All Blue Bird recalls →
Source: NHTSA recall database, campaign 04V388000 (manufacturer number R04HW). Data last verified Sep 14, 2026.