R13WT DATE: DECEMBER 31, 2013 TO: U.S. DEALERS SUBJECT: R13WT PARKING BRAKE PEDAL UNINTENTIONAL RELEASE This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Blue Bird has decided that a defect which relates to motor vehicle safety exists in certain 2014 and 2015 model year All American and Vision model school buses equipped with hydraulic brakes manufactured from September 06, 2013 through December 06, 2013. Due to a manufacturing process defect, the park brake pedal arm linkage can fracture causing an unintentional release of the parking brake without warning. If the park brake pedal arm linkage were to fail, the bus could roll unexpectedly when parked which could cause property damage, personal injury or death. Blue Bird recommends these vehicles not be operated and that wheel chocks be placed on the tires to prevent the vehicle from rolling unexpectedly until the parking brake pedal assemblies are replaced. Blue Bird is conducting a recall to correct this defect. Buses with this defect must be modified according to the enclosed instructions for Recall R13WT. If our records indicate affected buses were delivered in your service area, a printout identifying affected buses is enclosed. Dealers should verify correct owners and assure that complete shipping addresses are provided for each listed vehicle. You may have already completed some of these vehicles. If so, please provide the body numbers to Blue Bird Recall Administration so a notice will not be sent to the owner. If you have in your possession or have sold a bus that was purchased from another dealer that may be affected by this recall, please notify me at 478-822-2242. BLUE BIRD BODY COMPANY P.O. Box 937 402 Blue Bird Blvd Fort Valley, Georgia (478) 825-2021
Page 2 R13WT Owners are being advised to contact their Blue Bird dealers to obtain parts or to arrange a time to have this work performed. For Recall R13WT only, dealers must order the required replacement parts from Blue Bird Service Parts. Dealers must file for reimbursement for replacement parts by submitting the part in the Other Charges section of the campaign claim under Purchased Recall Parts, Priority order charges/freight invoiced by BB Service Parts, must be submitted under Recall R13WT in Other Charges under Freight. Recall R13WT will be set up in iwarranty so dealers may file for labor. Labor time to remove the original park brake pedal assembly and install a new park brake pedal assembly is 0.42 hours (25 minutes) per bus. Dealers may submit campaign claims in Blue Bird iwarranty. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Dealers are reminded of their responsibilities under section 154 of The National Traffic and Motor Vehicle Safety Act of 1991. Dealers are required to complete modifications on units in their inventory before delivering to the final owner. Reference Blue Bird Body Company Distributor Memo No. 42-92. Questions regarding this recall campaign should be directed to me at (478) 822-2242. Thank you, Bill Coleman Bill Coleman Corporate Recall Administrator Blue Bird Corporation
R13WT December 31, 2013 Dear Blue Bird Owner: This important safety recall notice applies to your buses identified by both Blue Bird Body Number and Vehicle Identification Number (VIN) on the enclosed yellow cover sheet. This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Blue Bird has decided that a defect which relates to motor vehicle safety exists in certain 2014 and 2015 model year All American forward engine and Vision model school buses equipped with hydraulic brakes manufactured from September 06, 2013 through December 06, 2013. Due to a manufacturing process defect, the park brake pedal arm linkage can fracture causing an unintentional release of the parking brake without warning. If the park brake pedal arm linkage were to fail, the bus could roll unexpectedly when parked which could cause property damage, personal injury or death. Blue Bird recommends these vehicles not be operated and that wheel chocks be placed on the tires to prevent the vehicle from rolling unexpectedly until the parking brake pedal assemblies are replaced. Blue Bird is conducting a recall to correct this defect. Buses with this defect must be corrected immediately according to the enclosed instructions for Recall R13WT. Parts and labor required to complete Recall R13WT, according to the attached instructions, will be provided at no cost to you. If you no longer own the subject bus(es), please complete the appropriate section of the yellow parts request sheet and return to Blue Bird in the enclosed pink postage prepaid envelope. You should contact your Blue Bird dealer to have this recall performed. Or, if you prefer, you may perform this recall yourself or have a qualified repair facility convenient to you perform this recall. A qualified technician should perform this recall. If you elect to perform this recall yourself, or have a qualified repair facility convenient to you perform this recall you will need to contact your Blue Bird Dealer to obtain recall parts. The required parts will be shipped to you or the repairing facility at No Charge. BLUE BIRD BODY COMPANY P.O. Box 937 402 Blue Bird Blvd Fort Valley, Georgia (478) 825-2021
Page 2 R13WT Labor time allowed to remove the original park brake pedal assembly and to install a new park brake pedal assembly 0.42 hours (25 minutes) per bus. If you perform Recall R13WT, or have a qualified repair facility convenient to you perform this recall, reimbursement for labor may be obtained by completing the pink request for reimbursement sheet provided and returning it to Blue Bird in the enclosed pink postage prepaid envelope. If the modifications directed by this notification were performed on your bus prior to the receipt of this recall notification, complete and sign the recall reply sheet and attached a copy of the work order/invoice. Mail the documents in the pink self-addressed postage paid envelope included with the recall notification to Blue Bird for warranty consideration. Reimbursements will be made in accordance with the requirements of the National Highway Transportation Safety Act, Title 49 Code of Federal Regulations, Parts 573 and 577. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. If Blue Bird Body Company should fail to or is unable to remedy this condition without charge to you, you may contact: ADMINISTRATOR NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION 1200 NEW JERSEY AVENUE, SE WASHINGTON, D.C. 20590 Or, you may call The National Highway Traffic Safety Administration toll free at: Or, go to: HTTP:/WWW.SAFERCAR.GOV 1-888-327-4236 TTY 1-800-424-9153 Questions regarding this recall campaign should be directed to me at (478) 822-2242. Thank you, Bill Coleman Bill Coleman Corporate Recall Administrator BLUE BIRD CORPORATION
ISSUE _ The parking brake pedal arm linkage may not have been manufactured correctly and if it were to fail, the bus could roll unexpectedly when parked. Blue Bird recommends that these buses not be operated and that wheel chocks be placed on the tires to prevent the bus from rolling unexpectedly until the parking brake pedals are replaced. CORRECTIVE ACTION ---- _ Replace original parking brake pedal assembly with new replacement parking brake pedal assembly. Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand the recommended procedures. PROCEDURE R 1 3 W T---- Models Affected: Certain 2014 & 2015 All American Front Engine and Vision Buses Equipped with Hydraulic Brakes Always wear safety glasses. 1. Park bus on a level surface, apply parking brake, switch engine off, remove ignition key. 2. Chock wheels then release parking brake. 3. Park brake cable tension must be released. Locate bellcrank at transmission. (Fig. 1) Using a pipe wrench adjusted to the bellcrank width in area shown in Fig 1, rotate bellcrank counter clockwise to remove cable tension and then remove clevis pin. 4. Disconnect parking brake release handle by removing the cotter pin and flat washer and set aside for use later. (Fig. 2) Fig. 1 --R E C A L L Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated or approved by the vehicle and component manufacturer. C A M P A I G WARNING: Always follow all Federal, State, Local and Shop safety standards and use proper safety equipment when performing these procedures. Thoroughly read and understand all instructions before performing this procedure. Fig. 2 Page 1 of 8
5. Disconnect brake switch connector (Fig. 3) and solenoid connector, if present. (Fig.4) Fig. 3 Solenoid connector (Park brake assembly with optional solenoid shown) Brake Switch Connector F Fig. 4 R E C A L L C A M P A I G N -- R 1 3 W T --- Page 2 of 8
6. Remove cotter pin, then the flat washer from release handle mechanism. (See Fig. 5) Note: Retain these parts for installation of new park brake lever assembly. Fig. 5 7. Using a ½ inch socket and ratchet remove both mounting bolts (Fig. 6). Ensure spacer on lower mounting bolt between park brake assembly and panel and all washers are saved for reinstallation. (Fig. 7) Pedal assembly mounting Bolts Remove cotter pin and flat washer Fig. 6 Fig. 7 Save spacer & washers R E C A L L C A M P A I G N -- R 1 3 W T --- Page 3 of 8
8. Rotate cable in assembly so one of the clips is in line with opening. (Fig. 8) Fig. 8 9. A modified wrench (Fig. 8) will be provided with each order consisting of a 13mm wrench with a slot cut in the top side of the box end and machining the hex open to approximately.585 Dia. This will give enough clamp pressure to depress the locking tabs. Modified wrench to aid in removing cable Fig. 9 10. Using the modified wrench, slide wrench down over cable connector. (Fig. 10) Fig. 10 Cable clip shown in line with opening Wrench shown over cable connector R E C A L L C A M P A I G N -- R 1 3 W T --- Page 4 of 8
11. Slide modified wrench over connector (Fig. 11) to disengage the locking tabs. Modified Wrench Fig. 11 12. Once wrench is properly located, pull cable straight out to remove from assembly. (Fig. 12) Fig. 12 Slide wrench in direction as shown by arrows Pull cable in direction of arrows R E C A L L C A M P A I G N -- R 1 3 W T --- Page 5 of 8
13. Once cable is disengaged from assembly position pedal in a full up position. (Fig. 13) Fig. 13 14. To remove, lift cable end from the retainer and separate from park brake lever assembly. (Fig. 14) Fig. 14 Pedal in full up position R E C A L L C A M P A I G N -- R 1 3 W T --- Page 6 of 8
15. Flip the pedal assembly over and position cable connection as shown. (Fig. 15) Fig. 15 16. Installation is in reverse order. Ensure spacer (Fig. 16) retained in Step 6 is placed between box assembly and park brake to prevent damage to assembly when installing lower mounting bolt. Fig 16 Cable position Spacer (retained in Step 7) R E C A L L C A M P A I G N -- R 1 3 W T --- Page 7 of 8
17. Be sure to reattached brake release lever. 18. Be sure to reattached cable at bellcrank on transmission. 19. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition. 20. Dispose of removed pedal assembly in accordance with all Federal, state and local regulations. 21. Remove chocks from wheels. 22. Return bus to service. PARTS LIST: Part No Qty Description 10020420 1 Pedal Assy, Brake, Park, Reinforced, Without Solenoid 10020421 1 Pedal Assy, Brake, Park, Reinforced, With Solenoid NPN 1 per order Wrench, 13mm, modified R E C A L L C A M P A I G N -- R 1 3 W T -- Page 8 of 8