2010 Mci D4000 problems

What is wrong

Motor Coach Industries, Inc (MCI) is recalling certain model year 2009-2011 D4000 and D4500 and 2010 D4505 motor coaches equipped with LED lights interior lights powered by either a Vansco or IO multiplex system. Due to the excessive power draw of the LED lights, heat may build up at the fuse block and connector, causing the components to melt.

Risk

If this occurs, the surrounding material may be damaged and will burn, increasing the risk of a fire.

Remedy

MCI will notify owners, and dealers will replace the fuse holders, free of charge. The recall began in July 2014. Owners may contact MCI customer service at 1‑847‑285‑2090. MCI's number for this recall is 388B. Note: This recall supersedes recall 12V‑250. Motorcoaches that were remedied under the previous campaign need to be remedied under this campaign as well.

Recall number 14V329000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain model year 2000-2012 D, E, G and J series coaches manufactured January 2000 through June 2011 and equipped with Sure Power battery equalizers containing a particular epoxy sealing, aka 'potting', compound. The specific potting compound used in the subject products for insulation was found to be capable of conducting electricity after being exposed to heat.

Risk

Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

Remedy

MCI will notify owners, and Sure Power will replace the equalizers, free of charge. Owners may contact MCI at 1‑847‑285‑2000. This campaign is MCI service bulletin 401.

Recall number 13V498000 · Recall details

What is wrong

Motor coach industries, inc (mci) is recalling certain model year 2009-2011 d4000, d4500 and 2010 d4505 motor coaches equipped with LED lights interior lights and powered by either a vansco or io multiplex system. Due to excessive power draw of the LED lights, heat may build up at the fuse block and connector, causing components to melt.

Risk

If this occurs, surrounding material may be damaged and will burn, increasing the risk of a fire.

Remedy

Mci will notify owners, and dealers will install re-designed wiring, free of charge. The recall began on july 17, 2012. Owners may contact mci at 1‑866‑624‑2622.

Recall number 12V250000 · Recall details

What is wrong

Motor coach industries (mci) is recalling certain model year 2003, and 2007-2012 e and j models along with model year 2007-2012 d4000, d4005, d4500, d4505, d4000istv motor coaches equipped with meritor wabco electronic stability control (ESC) modules, manufactured from october 2002, through october 2011. Under certain road and driving conditions, vehicle body roll and road inclination characteristics may adversely affect the slip angle calculation of the electronic stability control (ESC) system. This might cause the ESC to perceive an over steering situation and therefore apply the outer wheel brake on the front axle until the vehicle is perceived to be stable.

Risk

If the driver is slow to react during this ESC intervention, the vehicle may deviate from the intended line of travel, increasing the risk of a crash.

Remedy

Mci will notify owners and replace the control module free of charge. The safety recall began on january 4, 2012. Owners may contact mci customer service at 1‑800‑241‑2947.

Recall number 11V524000 · Recall details

What is wrong

Mci is recalling certain model year 2010-2011 d4500, d4505, and d4000 motor coaches. The affected pulley covers may lack certain welds required to keep the covers attached to the coach structure.

Risk

The cover will eventually fail as a result of fatigue, and the cover may become detached from the coach and fall and strike a person or object, resulting in personal injury or property damage.

Remedy

Mci will inspect and replace as necessary the idler pulley covers free of charge. The safety recall began on february 10, 2011. Owners may contact mci customer service at 1‑800‑241‑2947.

Recall number 11V016000 · Recall details

What is wrong

Mci is recalling certain model year 2010 d4000, d4005, d4500, d4505, e4500, and j4500 model motor coaches manufactured from september 2009 through may 2010, equipped with arvinmeritor front and tag axle assemblies. The suspect axles may have had improper torque applied to the hub/rotor/wheel adapter bolts during the assembly process. Reduced bolt torque could lead to vibration loosening of the bolt.

Risk

This could result in a loss of the wheel possibly resulting in a crash.

Remedy

Mci will notify owners and dealers will repair the motor coaches free of charge. The safety recall began on may 28, 2010. Owners may contact mci at 1‑800‑241‑2947.

Recall number 10V199000 · Recall details

In the fall of 2011, network contacts made ODI aware of four (4) incidents of drive shaft failure on the subject buses involving a loss of vehicle control.Two of the incidents were relatively low speed non-crash events; and two resulted in motor coach rollovers.All four events showed signs of a common failure mode.The incidents and crashes studied during this investigation all resulted from a series of complex events that began with the the yoke journal ears on the drive shafts fracturing.Once the drive shaft failed. it was not adequately contained by a drive shaft safety loop or structure.The spinning and unrestrained drive shaft caused severe damage to components on the steerable tag axle at the rear of the vehicle and created a forced steering condition.Once the rear of the bus was being forcibly steered by the tag axle, the driver lost control of the vehicle.These conclusions are based on the forensics evidence and testing conducted by the Vehicle Research and Test Center (VRTC).The VRTC test report is attached to this closing resume that provides details on how the test center was able to conclusively identify the defective components on the buses and demonstrate the sequence of events that caused the buses to crash.Prior to the drive shaft failure events, there were no indications of improper maintenance or that maintenance was required that would have prevented the incidents.Additionally, the U-joints on the incident vehicles were found to be in good working condition at the time of the failure. Finally, records of driver interviews indicated a sudden onset of the failure with no warning.Following the VRTC testing, MCI issued recall 14V‑335 involving certain model year 1993-1995 102DL3 motor coaches manufactured November 1992 to January 1995, and 2006 and 2008 D4505 motor coaches manufactured June 2005 to April 2008.The affected buses are equipped with a drive shaft with a compressed length of 30 inches or less (allowing it to escape containment if it fails), a steerable trailing tag axle equipped with a system that changes the axle caster when the vehicle is in reverse travel and no electronic stability control (ESC).Recall 14V‑335 addresses the concerns of this investigation.The ODI report cited above can be viewed at www-odi.the federal safety agency.dot.gov/owners/Searchreference: ODI Number 10447575.

EA12007

ODI has identified certain MCI coaches with powertrain configurations that may allow a driveshaft separated at the rearward universal joint to escape the guardian structure of the steerable tag axle and damage steering and braking components.The damaged components may increase the risk of a loss of vehicle control. The subject coaches include 806 model year 1992 through 2012 MCI D and E series motor coaches with steerable tag axles.This Preliminary Evaluation is being upgraded to an Engineering Analysis (EA12-007) to further study the alleged defect and to determine if a safety defect exists. The ODI report cited above can be viewed at www-odi.the federal safety agency.dot.gov/owners/Searchreference: ODI Number 10447575.

PE12007