NHTSA vehicle safety data
2004 Blue Bird Express 4000 Recalls & Complaints
The 2004 Blue Bird Express 4000 has 4 NHTSA recall campaigns on file as of October 21, 2026. try.vin has no NHTSA owner complaints on file for the 2004 Blue Bird Express 4000. Recall repairs are usually free at an authorized Blue Bird dealer.
NHTSA recall and complaint data for the 2004 Blue Bird Express 4000. Recall data is refreshed daily from NHTSA.
Battery Equalizers/DC-DC Converters-Possible Fire
NHTSA #13V480000 · Electrical System · NHTSA notice
Reported October 17, 2013 · Blue Bird Body Company
Potentially affected: 393 vehicles
Repair completion: 22.34% (latest rate the manufacturer reported to NHTSA; dataset updated October 21, 2026)
Blue Bird campaign R13WN · Owners notified December 17, 2013
Defect description
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.
Safety consequence
Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
Manufacturer remedy
Blue Bird will notify owners, and dealers will replace the equalizers, free of charge. The recall began on December 17, 2013. Owners may contact Blue Bird at 1-478-825-2021. Blue Bird's recall number is R13WN.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
BLUE BIRD/AIR DISC BRAKE
NHTSA #04V388000 · Service Brakes, Air — Disc · NHTSA notice
Reported August 4, 2004 · BLUE BIRD BODY COMPANY
Potentially affected: 156 vehicles
Blue Bird campaign R04HW · Owners notified August 10, 2004 · Vehicles built July 31, 2003 – June 25, 2004 (per NHTSA)
Defect description
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.
Safety consequence
A POTENTIAL FIRE IN THE WHEEL MAY OCCUR WHICH MAY RESULT IN PROPERTY DAMAGE OR PERSONAL INJURY.
Manufacturer remedy
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.
Notes
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).
BLUE BIRD/FMVSS 121/FRONT BRAKE AIR GAUGE
NHTSA #04V341000 · Service Brakes, Air — Supply — Check Valve · NHTSA notice
Reported July 19, 2004 · BLUE BIRD BODY COMPANY
Potentially affected: 48 vehicles
Blue Bird campaign R04HU · Owners notified July 30, 2004 · Vehicles built July 7, 2003 – June 25, 2004 (per NHTSA)
Defect description
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.
Safety consequence
LOSS OF AIR PRESSURE COULD RESULT IN LONGER STOPPING DISTANCES WHICH COULD RESULT IN A CRASH.
Manufacturer remedy
DEALERS WILL ADD THE REQUIRED CHECK VALVE TO THE FRONT AIR BRAKE SERVICE RESERVOIR TO INSURE COMPLIANCE WITH FMVSS NO. 121. THE RECALL BEGAN ON JULY 30, 2004. OWNERS SHOULD CONTACT BLUE BIRD AT 478-822-2242.
Notes
BLUE BIRD RECALL NO. R04HU.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
BLUE BIRD/STEERING LINKAGES
NHTSA #04V153000 · Steering — Linkages · NHTSA notice
Reported March 26, 2004 · BLUE BIRD BODY COMPANY
Potentially affected: 98 vehicles
Blue Bird campaign R04HR · Owners notified April 7, 2004
Defect description
ON CERTAIN MOTOR HOMES AND TRANSIT COACHES, INCORRECT TORQUE APPLICATION COULD HAVE BEEN APPLIED TO THE CLAMP BOLTS AND THE DRAG LINK.
Safety consequence
THIS COULD LEAD TO THE CLAMPS BECOMING LOOSE, CAUSING MISALIGNMENT OF THE STEERING AXLES, WHICH COULD RESULT IN A LOSS OF VEHICLE CONTROL, INCREASING THE RISK OF A CRASH.
Manufacturer remedy
DEALERS WILL REPLACE THE CLAMP BOLTS AND AND TIGHTEN TO THE REQUIRED TORQUE. OWNER NOTIFICATION BEGAN ON APRIL 7, 2004. OWNERS SHOULD CONTACT BLUE BIRD AT 478-822-2242.
Notes
BLUE BIRD RECALL NO. R04HR.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Other Blue Bird Express 4000 model years
Check your 2004 Blue Bird Express 4000 VIN
Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Blue Bird Express 4000 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.
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