1994–2004 Orion V Recall: CERTAIN TRANSIT BUSES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL…
NHTSA campaign 04V545000 · Structure · filed Nov 15, 2004 · verified Jul 30, 2026
The defect
CERTAIN TRANSIT BUSES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 217, "BUS EMERGENCY EXITS AND WINDOW RETENTION AND RELEASE." DURING SUBSEQUENT CLOSING OF AN EMERGENCY EXIT THE MOVING WINDOW FRAME INTERFERES WITH THE JAM FRAME STOP LOCATED IN MID SPAN ALONG THE LOWER EDGE OF THE WINDOW FRAME.
The risk
DURING THE USE OF AN EMERGENCY EXIT WINDOW, A WINDOW MAY NOT OPEN AFTER APPLYING THE REQUIRED FORCES ALLOWING A PERSON TO ESCAPE IN THE EVENT OF AN EMERGENCY.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →The fix — what to do
DEALERS WILL INSTALL TWO ALUMINUM BLOCKS EACH ATTACHED BY TWO SCREWS. THE MOVING WINDOW FRAME WILL NOT INTERFERE WITH THE JAM FRAME STOP. THE RECALL BEGAN MAY 1, 2005. OWNERS SHOULD CONTACT ORION AT 905-403-7832, EXT. 3335.
CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Affected vehicles
Related recalls
More Orion V recalls
- 2003–2008 Orion V and 1 other model — Specific potting compound used in the equalizers and…
- 2004–2008 Orion V and 1 other model — Turbine or compressor wheel may fail, resulting in…
- 1992–1998 Orion II and 3 other models — Power Train
- 2002–2007 Orion V and 1 other model — Interior Lighting
- 2000–2008 Orion V — Equipment Adaptive/mobility
Other campaigns involving Orion vehicles
Source: NHTSA recall database, campaign 04V545000. Data last verified Jul 30, 2026.