1991 Blue Bird Conventional Recalls

Recalls on record Updated July 2026

The 1991 Blue Bird Conventional has 6 NHTSA recall campaigns affecting an estimated 68,336 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 7 complaints with NHTSA, most often about the fuel/propulsion system. Last updated July 5, 2026.

Recall campaigns

ENGINE AND ENGINE COOLING 07V398000 2007-08-30 1,847 affected
Defect

CERTAIN BLUE BIRD CONVENTIONAL SCHOOL BUSES BUILT WITH AN OPTIONAL FIREWALL HEATER HOSE CONNECTOR ON THE DRIVER'S SIDE OF THE BUS AND MANUFACTURED FROM NOVEMBER 21, 1985, THROUGH SEPTEMBER 14, 1993.

Consequence

IN THE EVENT THE HEATER HOSE RUPTURE SOR THE HOSE CONNECTION SEPARATES, HOT ENGINE COOLANT MAY CONTACT THE DRIVER AND MAY CAUSE INJURY.

Remedy

BLUE BIRD WILL NOTIFY OWNERS AND REPAIR THESE BUSES BY INSTALLING A METAL PROTECTIVE SHIELD OVER THE HEATER HOSES FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 15, 2008. OWNERS CAN CONTACT BLUE BIRD AT 478-822-2242.

SEATS 99V018000 1999-06-15 41,260 affected
Defect

VEHICLE DESCRIPTION: SCHOOL BUSES. THE WALL SIDE ATTACHING BOLTS FOR SOME OF THE PASSENGER SEATS MAY HAVE BEEN INSTALLED TOO CLOSE TO THE EDGE OF THE SEAT LEDGE AND IN THE WRONG ATTACHING HOLE RESULTING IN WEAKENING OF THE SEAT LEDGE AT THE ATTACHMENT POINTS.

Consequence

IN THE EVENT OF A FRONTAL CRASH, THE REAR ATTACHING BOLT OF THESE SEATS COULD PULL OUT OF THE SEAT LEDGE INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.

Remedy

BLUE BIRD WILL FURNISH TO DISTRIBUTORS AND OWNERS, PARTS AND INSTRUCTIONS NECESSARY TO STRENGTHEN THE PASSENGER SEAT ATTACHMENT AT THE WALL SIDE.

STRUCTURE 96V073000 1996-05-03 18,000 affected
Defect

PASSENGER'S CLOTHING CAN UNKNOWINGLY BECOME CAUGHT IN THE FORWARD HANDRAILS AT BUS DOORS WHEN EXITING THE BUS.

Consequence

WHEN A PASSENGER'S CLOTHING BECOMES CAUGHT IN THE HANDRAIL, AND THE BUS DRIVER CLOSES THE DOOR AND PUTS THE VEHICLE IN MOTION, THE INDIVIDUAL IS SUBJECT TO BEING DRAGGED BY THE BUS. THIS CAN RESULT IN SERIOUS INJURY OR DEATH.

Remedy

OWNERS WILL BE DIRECTED TO REMOVE ALL FORWARD HANDRAILS. PROVISIONS WILL BE MADE FOR THOSE OWNERS OPERATING IN STATES WHICH MANDATE A FORWARD HANDRAIL THAT A REPLACEMENT HANDRAIL WILL BE PROVIDED.

LATCHES/LOCKS/LINKAGES 93V080000 1993-05-17 1,932 affected
Defect

A WELD IN THE DOOR LOCK ASSEMBLY USED ON REAR AND/OR SIDE EMERGENCY DOORS CAN BE OVERSTRESSED AND BREAK. WHEN THIS OCCURS, A CLOSED DOOR CANNOT BE OPENED, OR IF OPEN IT CANNOT BE LATCHED.

Consequence

AN EMERGENCY DOOR THAT WILL NOT OPEN PRESENTS ANINCREASED RISK OF INJURY TO PASSENGERS ATTEMPTING TO LEAVE A BUS IN ANEMERGENCY SITUATION. A DOOR LOCK WHICH WILL NOT CLOSE PRESENTS A RISK OF APASSENGER ACCIDENTALLY FALLING OUT OF THE BUS.

Remedy

REPLACE THE DEFECTIVE DOOR LOCKS.

LATCHES/LOCKS/LINKAGES 92V184000 1992-12-24 912 affected
Defect

THE ELECTRIC VANDAL LOCK CENTER PLUNGER CAN TAP THE CONTROL LOCK PIN, OF THE OUTWARD OPENING DOOR, WHICH CAUSES THE DOOR LOCK TO BECOME DISENGAGED.

Consequence

THE DISENGAGED DOOR LOCK ALLOWS THE DOOR TO OPEN WITHOUTPRIOR WARNING AND ENDANGER OCCUPANTS NEAR THE DOOR IF THE VEHICLE IS IN MOTION.

Remedy

MODIFY THE VANDAL DOOR LOCKS WITH BLUE BIRD SUPPLIED KITS.

SEAT BELTS 92V156000 1992-10-19 4,385 affected
Defect

SAFETY BELT RETRACTOR LOCKS UP WITH THE BELT IN THE STOWED POSITION.

Consequence

WHEN THE RETRACTOR LOCKS UP WITH THE BELT IN THE STOWEDPOSITION , THE DRIVER IS UNABLE TO USE THE SAFETY BELTS, RESULTING IN INCREASEDRISK OF INJURY IN A SUDDEN STOP OR ACCIDENT.

Remedy

MODIFICATION KITS WILL BE SHIPPED DIRECTLY TO THE OWNER FOR MODIFICATION OF THE SAFETY BELT RETRACTOR.

Complaints by component

FUEL/PROPULSION SYSTEM
7
Total complaints7

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection”

FUEL/PROPULSION SYSTEM · reported 2022-10-22

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection repaired by dealer…”

FUEL/PROPULSION SYSTEM · reported 2022-10-20

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection”

FUEL/PROPULSION SYSTEM · reported 2022-05-10

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection second crack 2-20-23 @…”

FUEL/PROPULSION SYSTEM · reported 2022-05-10

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection second crack 1-2-23 @…”

FUEL/PROPULSION SYSTEM · reported 2022-05-10

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection”

FUEL/PROPULSION SYSTEM · reported 2022-05-10

“* propane barrier tank bracket cracks at fastener locations * michigan state police identified as a violation *any fuel tank impact protection cage that fails to comply with fmvss301 * inspected by michigan state police, oem bus dealer *no warning, found on safety inspection”

FUEL/PROPULSION SYSTEM · reported 2022-05-10
Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 1991 Blue Bird Conventional as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.