Recall 22V578 affects 49 2018-2023 Blue Bird Vision buses for corroding fuel return lines. Repair will be free at franchised Blue Bird dealers once available.
Blue Bird is recalling 49 2018-2023 Vision, Vision Transit Bus, and Vision School Bus buses equipped with Roush GEN 4 and GEN 5 LPG fuel return lines. Road debris can damage zinc plating on the line; where dissimilar metals touch, corrosion can lead to a fuel leak and fire risk, and the Blue Bird dealer repair will be free once available.
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What's wrong?
The fuel return line on these 2018-2023 Blue Bird Vision, Vision Transit Bus, and Vision School Bus models is part of the Roush LPG fuel system. It carries unused fuel back toward the tank, and its connector uses a zinc-plated carbon steel fitting next to a stainless-steel crimp collar.
On affected buses operated in Salt Belt states, road debris can chip or break away the zinc plating that protects the fitting. Once road salt and moisture reach the exposed metal, the contact between the carbon steel fitting and stainless-steel collar can start corrosion. Over time, that corrosion can weaken the connector fitting and lead to a fuel leak.
Owners or fleet staff can inspect the fuel return line connector fitting for heavy red rust before a leak appears. That red rust is the warning sign to report when calling the Blue Bird dealer or service department.
Who's affected?
Spans the Vision, Vision Transit Bus, and Vision School Bus across the 2018-2023 model years, all tied to the same fuel system component.
| 2022 Blue Bird Vision Transit Bus | fuel system |
|---|---|
| 2019 Blue Bird Vision | fuel system |
| 2021 Blue Bird Vision Transit Bus | fuel system |
| 2023 Blue Bird Vision Transit Bus | fuel system |
| 2020 Blue Bird Vision Transit Bus | fuel system |
| 2018 Blue Bird Vision | fuel system |
| 2021 Blue Bird Vision School Bus | fuel system |
| 2020 Blue Bird Vision School Bus | fuel system |
| 2022 Blue Bird Vision School Bus | fuel system |
| 2023 Blue Bird Vision School Bus | fuel system |
| Units affected | 49 |
| Field incidents | NHTSA has logged 19 field incidents to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
A corroded fuel return line can leak fuel and increase the risk of a fire. A significant amount of red rust on the fuel return line connector fitting is a warning sign before a leak, so schedule service soon if your VIN is included. Repair will be free at any franchised Blue Bird dealer once available.
What should I do?
- Check your VIN to confirm your 2018-2023 Blue Bird Vision, Vision Transit Bus, or Vision School Bus is included in this recall.
- Watch for Blue Bird's owner letter if you have not received it; owner letters were mailed May 24, 2023.
- Contact Blue Bird customer service at 1-478-822-2242 to confirm when the free fuel-return-line replacement is open.
- Reference recall number 22V578 when you call, and ask whether Blue Bird recall R22BX-NSB applies to your bus.
- Avoid using any included bus that has a fuel smell or visible fuel leak, and keep it away from ignition sources until Blue Bird gives repair instructions.
What happens at the repair
At the dealer, a Blue Bird technician will replace the fuel return lines that are part of the Roush LPG conversion fuel system. Because this recall is still listed as under development, treat that as the final dealer repair once Blue Bird opens it, not a repair to schedule before it is available. Parts and labor are covered under the recall. Roush's reimbursement plan covers the labor cost for recall related repairs at no cost to the dealer or vehicle owner.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 4, 2022 | NHTSA published the recall |
|---|---|
| September 28, 2022 | Dealer notification began |
| September 28, 2022 | Dealer notification ended |
| September 28, 2022 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| September 28, 2022 | Interim owner notification (was planned for this date) |
| May 24, 2023 | Owner notification mailed |
Frequently asked questions
What is recall 22V578?
Recall 22V578 covers 49 2018-2023 Blue Bird Vision buses with Roush fuel return lines in GEN 4 and GEN 5 LPG Conversion Systems. Road debris can damage the zinc plating, allowing corrosion on the fuel line. Blue Bird dealers will replace the fuel return lines for free.
What should I do if my 2018-2023 Blue Bird Vision bus is on this recall?
Check your VIN to confirm your specific bus is included in recall 22V578. If it is, contact a franchised Blue Bird dealer and reference recall number 22V578 or Blue Bird recall R22BX-NSB. Ask the dealer to confirm parts and service timing before bringing the bus in.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. For recall 22V578, Blue Bird dealers will replace the affected fuel return lines free of charge.
What is the safety risk?
The safety risk is a fuel leak and fire. NHTSA campaign 22V578 says corrosion on the fuel line can allow fuel to leak, increasing fire risk. If your VIN is included, arrange the free dealer repair and ask Blue Bird customer service at 1-478-822-2242 about any handling instructions.
When were owners notified about this Blue Bird recall?
Blue Bird mailed owner notification letters on May 24, 2023. If you bought the bus used or did not receive the letter, the VIN still decides whether recall 22V578 applies. Check your VIN, then call a Blue Bird dealer with the recall number.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/22V578000 |
|---|---|
| Blue Bird customer service | 1-478-822-2242 |
| NHTSA recall # | 22V578 |
| NHTSA recall # (full) | 22V578000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Document (PDF) (PDF)
- Download Recall Document (PDF) (PDF)
- Download Owner Notice (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Recall Document (PDF) (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →