R22BX-SB – Corrosion May Cause Fuel Line Leak – 2017-2023 Blue Bird Vision School Buses

August 4, 2022 NHTSA CAMPAIGN NUMBER: 22V579000

Corrosion May Cause Fuel Line Leak

A corroded fuel line can leak fuel, increasing the risk of a fire.


NHTSA Campaign Number: 22V579

Manufacturer Blue Bird Body Company


Potential Number of Units Affected 4,900



Blue Bird Body Company (Blue Bird) is recalling certain 2017-2023 Blue Bird Vision school buses equipped with Roush fuel return lines included in GEN 4 and GEN 5 LPG Conversion Systems that were installed on vehicles sold or registered in Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, Washington D.C., West Virginia, and Wisconsin. The zinc-plating on the fuel return line may break away when contacted by road debris, causing two dissimilar metals on the fuel line to contact each other and corrode.



Dealers will replace the fuel return lines, free of charge. Interim owner notification letters are expected to be mailed on September 28, 2022. Second letters will be mailed when the remedy is available. Owners may contact Blue Bird’s customer service at 1-478-822-2242. Blue Bird’s number for this recall is R22BX-SB.



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.nhtsa.gov.


2022 Blue Bird Vision
2022 Blue Bird Vision


Chronology :

October, 2020: Roush was informed that two Blue Bird school buses in Pennsylvania had experienced apparent corrosion-caused fuel return line fitting failures about three weeks apart.

Roush started to investigate service history, engineering, and supplier quality. Several additional similar warranty claims were reported in 2021.

Spring 2022, Roush had received a total of 19 corrosion warranty claims, with no fires. These claims arose solely in Salt Belt states and involved vehicles with various mileage and manufacturing dates.

Roush began its Salt Belt and non-Salt Belt geographic field and laboratory investigation in 2021. In total, Roush inspected (and rated for degree of corrosion) the fittings on more than 166 representative vehicles as described in the “Describe the Cause” section above. The inspections identified the vehicle make, model, part number, part location, orientation, mileage, alteration date, geographic location, and route characteristics. Some non-leaking fittings observed with exterior corrosion were dissected to ascertain the extent of any internal compromised metal.

Roush also conducted two types of laboratory salt spray testing. The ASTM B117 salt spray testing varied the orientation of the fittings in the salt test chamber (parallel to ground, perpendicular, 45 degrees, reversed male tube directions). Roush’s modified salt spray testing included a road debris pecking simulation. Roush then tested fittings equipped with additional spiral wrap protection, with braided loom protection, and with a combination of the two protections.

Based on the results of its investigation, in late May 2022, Roush decided to submit a 573.

August 1, 2022: Blue Bird Corporation was notified by Roush of the Safety Recall Campaign for return line fittings.


22E049 – Corrosion May Cause Fuel Line Leak – Roush – GEN 4 & GEN 5 LPG Conversion Systems


22E049 – Corrosion May Cause Fuel Line Leak – Roush – GEN 4 & GEN 5 LPG Conversion Systems


7 Affected Products




3 Associated Documents

Recall Acknowledgement

RCAK-22V579-3231.pdf 646.541KB



Defect Notice 573 Report

RCLRPT-22V579-8949.PDF 216.73KB



Recall 573 Report- -8/12/2022

RCLRPT-22V579-4429.PDF 216.851KB



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Last update on 2022-09-29 / Affiliate links / Images from Amazon Product Advertising API

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