There is an issue with the braking systems on the Bluebird buses which cause the brake lights to illuminate constantly, fail to illuminate, limit acceleration, and/or receive a "loss of brake input" warning message on the dash cluster. We have 43 Buses of like Year Models ranging from 2021 - 2022 Bluebird, Vision, that we have documented 38 separate repairs for 28 buses in our fleet related to the braking system. The brake pedal experiences excessive back travel that causes damage to the brake switch (part number 10026469). The cause of the excessive back travel is a gap between the pedal stop, rubber bumper, and switch mounting bracket. There is not enough adjustment area in the switch mounting bracket to prevent the excessive brake pedal back travel. Once the brake switch becomes damaged multiple issues become possible. There is potential for constant brake light illumination, no brake light illumination, a loss of brake input warning message, and sudden stopping of vehicle acceleration. The brake light illumination is not found consistently during the pre-trip inspection process due to the usage of the pre-trip lighting sequence button that provides false confidence that the brake lights are working properly. What component or system failed or malfunctioned, and is it available for inspection upon request? The brake switch failed parts are being returned to Bluebird for Warranty parts replacement. How was your safety or the safety of others put at risk? The multiple symptoms listed above produce various safety issues for the buses and other vehicles on the road. Has the problem been reproduced or confirmed by a dealer or independent service center? Yes, Multiple vehicles have experienced the same issue and the switches are being replaced as a repair. Multiple vehicles have reoccurring issues with the replaced switches. The local dealer has gone to the manufacturing facility and addressed the issue them.

Source: NHTSA complaint ODI #11504844 · view all complaints for this vehicle at nhtsa.gov