Mci D4000 recalls

What is wrong

Motor Coach Industries (MCI) is recalling certain 102DL3, 102D3, MC12PTV, E4500, D4000, 102D3ISTV, D4500, J4500, D4000ISTV, D4005, D4505, and J3500 transit buses. Please refer to MCI's recall report for specific model year information. The front door lower curb view glazing material is incorrect. As such, these vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) number 205, "Glazing Materials."

Risk

The incorrect window glazing material may reduce the driver's visibility, increasing the risk of a crash.

Remedy

MCI will replace the glass, free of charge. Owner notification letters were mailed February 4, 2026. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is 22-005.

Recall number 25V853000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2014-2018 D4000, 2013-2019 D4005, 2013-2023 D4500, 2013-2020 D4505, and 2021-2024 D45CRT coaches equipped with a Ricon wheelchair lift. The red beacon lighting on the Threshold Warning System (TWS) may not be bright enough. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 403, "Platform Lift Systems."

Risk

Beacons that do not provide proper illumination may be less visible to wheelchair lift users, increasing the risk of injury.

Remedy

MCI will work with Ricon to replace the TWS kits, free of charge. Owner notification letters were mailed March 21, 2024. Owners may contact MCI customer service at 1‑800‑241‑2947.

Recall number 24V073000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2019-2022 D4000 ISTV, D4500, 2021 D4000, D4520, 2020-2021 D4505, D4005, 2020-2022 D45CRTLE, and 2019-2021 J4500 vehicles equipped with certain Cummins X12 diesel engines. The fuel tubes between the fuel rail and the injectors for cylinders four, five, and six may fatigue and crack, which can result in a high pressure fuel leak.

Risk

A high pressure fuel leak in the presence of an ignition source can increase the risk of a fire.

Remedy

On engines with 75 miles or less, Cummins dealers will install vibration isolators to the fuel tubes. Engines with more than 75 miles will receive new fuel tubes with vibration isolators. Repairs will be performed free of charge. Owner notification letters were mailed March 11, 2022. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is R21-028.

Recall number 21V971000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2018 D4000, 2018-2020 D4005, D4000ISTV, 2017-2020 D4500, D4505, 2018-2021 J3500, 2017-2021 J4500, 2020 D4520, and 2018-2021 D45CRTLE motorcoaches. The Main Distribution Panel (MDP) located within the battery compartment contains a circuit board that may fail.

Risk

MDP circuit board failure can result in a fire or an unexpected vehicle shutdown, increasing the risk of a crash.

Remedy

MCI Service Centers will remove the MDP and install a new main disconnect and circuit breaker panel, free of charge. Owner notification letters were mailed November 12, 2021. Owners may contact MCI's customer service at 1‑800‑241‑2947. MCI's number for this recall is R21-010.

Recall number 21V748000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2017-2018 D4000, 2017-2019 D4005, D4000ISTV, D4505, 2017-2020 D4500, J4500, 2018-2020 D45CRTLE, and 2018-2021 J3500 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.

Risk

A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy

Dealers will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is R21-009.

Recall number 21V364000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2018-2020 D4000, D4005, D4500, D4505 and D45CRTLE buses manufactured with electric cooling fans (E-fan) for the radiator and charge air cooler, Borg Warner 55SI model dual alternator configuration (with a sense stud and wire), and Parker Vansco Multiplexing Module (VMM) Multiplex system. A build-up of debris, corrosion, and/or water flow could cause a high resistance path to ground for the sense stud on the back of the alternator and cause the alternator to produce excessive voltage output, which may exceed the threshold limit currently programmed in the VMM and result in a loss of engine power and vehicle shutdown.

Risk

If the engine shuts down or loses power while the vehicle is in motion, this may increase the risk of a crash.

Remedy

MCI will notify the affected owners, and dealers will install a new application code in the Parker VMM multiplex modules increasing the overvoltage threshold limit, free of charge. The recall began July 23, 2020. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is SB 479.

Recall number 20V352000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2015-2016 D4000, 2015-2020 D4500 and D4505, 2016-2020 J4500, 2018 J3500, and 2017 D4005 buses. The seat belts may not extend from the retracted position, rendering the seat belt unusable. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standards (FMVSS) number 208, "Occupant Crash Protection," and number 209, "Seat Belt Assemblies."

Risk

Inability to use the seat belt may increase the risk of injury in the event of a crash.

Remedy

MCI will notify the affected owners, and dealers will inspect and replace the seat belts, as necessary, free of charge. MCI issued owners an interim notification June 26, 2020. The recall began January 13, 2021. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is SB 482.

Recall number 20V242000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2011-2016 D4500, D4505, D4000, D4005, and D4000 ISTV motor coaches equipped with ISX engines. Due to vibrations, the exhaust bellow pipes develop a hole.

Risk

If the pipe develops a hole, during a regeneration cycle, hot exhaust gases may leak out, increasing the risk of a fire.

Remedy

MCI will notify owners, and dealers will replace the bellows pipe assembly with an improved part, free of charge. The recall began July 10, 2018. Owners may contact MCI customer service at 1‑800‑241‑2947.

Recall number 18V309000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain 2011-2012 MCI D4000, D4005, D4500 and D4505 coaches equipped with Cummins ISX 12 liter engines. The vehicles may have an incorrectly installed exhaust bellow pipe, resulting in a bend in the pipe which can cause its premature failure.

Risk

If the pipe fails and a diesel regeneration cycle occurs, the hot exhaust gases will increase the risk of a fire.

Remedy

MCI will notify owners and dealers will inspect and replace any deformed or failed bellow pipes if necessary, free of charge. The recall began on June 15, 2017. Owners may contact Motor Industries at 1‑800‑241‑2947. MCI's number for this recall is SB 397B.

Recall number 17V337000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain model year 2011-2013 and 2015 J4500 coaches manufactured November 18, 2011, to July 10, 2015, 2011-2012 and 2014-2015 D4000 coaches manufactured manufactured September 24, 2010, to September 5, 2015, 2011-2013 and 2015-2016 D4005 coaches manufactured January 17, 2011, to November 23, 2015, 2012-2014 and 2016 D4000ISTV coaches manufactured July 18, 2012, to December 2, 2015, 2010-2016 D4500 coaches manufactured April 15, 2010, to December 18, 2015 and 2011-2016 D4505 coaches manufactured December 15, 2010, to December 4, 2015. The affected buses are equipped with certain Recaro Ergo-M Commercial Bus Driver Seats that have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.

Risk

If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.

Remedy

MCI will notify owners and dealers will inspect the seats and determined if welds are missing. Any J-Bracket that is missing welds will be removed and replaced, free of charge. The recall began on February 15, 2016. Owners may contact MCI at 1‑800‑241‑2947. MCI's number for this recall is SB 431.

Recall number 16V020000 · Recall details

What is wrong

Motor Coach Industries, Inc. (MCI) is recalling certain model year 2015 D4000 vehicles manufactured June 8, 2015, to July 20, 2015, D4005 vehicles manufactured March 18, 2015, to July 10, 2015, D4500 vehicles manufactured December 19, 2014, to July 20, 2015, and D4505 vehicles manufactured December 18, 2014, to July 15, 2015. In the affected vehicles, the fuse block assembly for the heating, ventilation and air conditioning motors in the battery compartment may have been assembled incorrectly.

Risk

The incorrectly assembled fuse block may not protect the circuit and the connections may arc, increasing the risk of a fire.

Remedy

MCI will notify owners, and dealers will replace the fuse block assembly, free of charge. The recall began on November 2, 2015. Owners may contact MCI customer service at 1‑800‑241‑2947.

Recall number 15V580000 · Recall details

What is wrong

Motor Coach Industries (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured November 12, 2011, to July 11, 2012, and 2014-2015 D4500 motorcoaches manufactured July 4, 2014, to April 30, 2015. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.

Risk

If the engine oil comes into contact with a hot surface, it can increase the risk of a vehicle fire.

Remedy

MCI will notify owners, and Cummins service centers will administer the repairs which include securing the ends of the 90-degree elbow and reprogramming the electronic control module (ECM) with software that can adjust the engine output under misfire conditions to limit crankcase pressures. These repairs will be performed free of charge. The recall began on June 18, 2015. Owners may contact MCI customer service at 1‑800‑241‑2947 or Cummins Inc. at 1‑800‑343‑7357. MCI's number for this recall is SB 423.

Recall number 15V276000 · Recall details

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, Inc. (MCI) is recalling certain model year 2014 D4000, D4005, D4000ISTV, D4500, D4505, and J4500 motor coaches manufactured July 2013 to April 2014. The multiplex electrical systems controller may unintentionally turn off the vehicle's headlights while the vehicle is in gear.

Risk

If the headlights turn off while the vehicle is in operation, the driver's visibility may be reduced, increasing the risk of a crash.

Remedy

MCI will notify owners, and dealers will update the multiplex controller software, free of charge. The recall began in July 2014. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is 413.

Recall number 14V370000 · Recall details

What is wrong

Motor Coach Industries, Inc. (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured March 2011 through July 2012 and equipped with certain Cummins Westport model ISL G. Condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold pressure sensor.

Risk

The improper operation of the sensor could induce elevated exhaust temperatures or flames from the exhaust pipe, increasing the risk of a vehicle fire or burn injury to a person near the exhaust pipe.

Remedy

MCI will notify owners, and authorized Cummins service facilities will upload a new ECM calibration, free of charge. The recallbegan on April 16, 2014. Customers may contact MCI at 1‑847‑285‑2090 or Cummins Inc. at 1‑800‑343‑7357. MCI's number associated with this campaign is 405.

Recall number 14V085000 · 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 (MCI) is recalling certain model year 2012-2013 D4000, D4000ISTV, D4005, D4500, and D4505 motorcoaches manufactured from May 2012 through December 2012 and equipped with a Cummins ISX EPA 2010 engine. In the affected buses, the bellows pipe in the exhaust system may have been incorrectly assembled, which could result in a failure of the pipe during operation.

Risk

During a regeneration process to clean exhaust emissions, if the bellows pipe has failed, the hot exhaust gases may not be contained, resulting in a fire.

Remedy

MCI will notify owners and dealers will inspect and replace the bellows pipes, as necessary, free of charge. The recall began on April 29, 2013. Customers may contact MCI at 1‑847‑285‑2000.

Recall number 13V142000 · 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

What is wrong

Mci has notified the federal safety agency of a defect in certain model year 2009 d4000 and model year 2008-2010 d4500 and d4505 motor coaches fitted with ricon public use lifts. The restraint belt on these lifts was designed to prevent the lift from moving, unless the tongue of the belt is fully engaged and latched in the buckle. Ricon has discovered, however, that it is possible for the operator to insert the belt tongue into the buckle without fully engaging the latching mechanism. In this case, the restraint belt would appear to be latched, and the operator could run the lift. If the restraint belt tongue is not fully engaged into the restraint belt buckle, and latched, the lift may operate with an occupant on the platform.

Risk

The user of the lift could be injured should the lift move without the restraint belt properly buckled.

Remedy

Mci is working with ricon and ricon will be handling the remedy for this campaign. Please see ricon's defect report 09e-060. Ricon will provide customers with a warning decal and a dvd-based training aid. The recall is expected to begin during april 2010. Owners may contact ricon customer service at 1‑800‑322‑2884, emailing at [email protected].

Recall number 10V114000 · Recall details

What is wrong

Mci is recalling certain model year 2000-2009 d4000, model year 2001-2010 d4500 and model year 2005-2007 d4505 coaches equipped with ricon wheelchair lift (wcl) and a cassette-type wcl compartment door. The wheelchair lift may become disengaged from a locked position and slide unrestrained on its rollers in the storage structure, potentially breaking through the cassette door and extending beyond the outside of the door when the coach is in motion, particularly when the coach is making a left turn.

Risk

If the coach is in motion, potential injury to persons and/or damage to other vehicles or property could occur.

Remedy

Mci will provide parts and labor to install free of charge to customers, a ricon designed retrofit kit that includes a spring loaded lock mechanism. The safety recall began on march 31, 2010. Owners may contact mci customer service line at 1‑800‑241‑2947.

Recall number 10V087000 · Recall details

What is wrong

Mci is recalling certain model year 2005-2008 d4000, model year 2005-2009 d4500 and d4505 transit buses, equipped with caterpillar c13 engine and 50dn alternator. The alternator cable may become loose within the cable clamp, which could result in chafing of the alternator cable and possible arcing of the cable wires.

Risk

This could result in a fire.

Remedy

Mci will notify owners and replace the alternator cable clamp and related hardware free of charge. The safety recall began on november 30, 2009. Owners may contact mci customer service at 1‑800‑241‑2947.

Recall number 09V446000 · Recall details

What is wrong

Mci is recalling certain model year 2002-2009 d series coaches, equipped with luminator horizon LED side destination signs. The connector board can corrode due to an accumulation of moisture under the connector.

Risk

A short could occur, possibly causing smoke and fire.

Remedy

Mci will notify owners and luminator will repair the buses free of charge. Please see luminator's defect report 09e-054. The safety recall began on november 9, 2009. Owners may contact luminator at 1‑972‑516‑3033 or mci customer service at 1‑800‑241‑2947.

Recall number 09V432000 · Recall details

What is wrong

On certain motor coaches, the boost connector housing can fail over time, exposing the positive and negative terminals.

Risk

This could result in the grounding of an unprotected circuit and could lead to a thermal event if not corrected.

Remedy

Customers are being advised to remove the boost connector and discard it. Customers will be offered a new design boost connector as an alternative at no cost. The recall began on january 2, 2007. Owners may contact mci at 1‑800‑241‑2947.

Recall number 06V481000 · Recall details

What is wrong

On certain motor coaches equipped with a slide switch to control the defroster blower speed, there is a speed controller for each of the two defroster fan motors. The speed controller may fail causing the fan motor to operate continuously in the "high" speed mode, and the carrier slide switch may fail to reduce or otherwise control the fan motor speed.

Risk

The speed controller may overheat and result in a thermal even, such as smoking or possible fire.

Remedy

Dealers will replace the defroster speed controller free of charge. The recall began on july 20, 2006. Owners may contact motor coach at 1‑800‑241‑2947.

Recall number 06V241000 · Recall details

What is wrong

On certain motor coaches equipped with detroit diesel series 60 engines, the turbocharger compressors can fail.

Risk

A fire can result should the turbocharger fail.

Remedy

Detroit diesel is conducting this recall (please see 06e019000) and will remedy these motor coaches. The engines will be repaired free of charge. Owners may contact detroit diesel at 313‑592‑3708 or motor coach at 866‑624‑2622.

Recall number 06V140000 · Recall details

What is wrong

On certain motor coaches that have multiplex systems, when the coach's defroster motor is activated, certain high speed cell net controllers (hcnc) may lock up.

Risk

As a consequence of this lock up, the functions and systems that are part of the multiplex system will remain at their status immediately prior to the lockup. This could affect the electrical operation of brake lights, turn signals, ignition, instrumentation, etc.

Remedy

Owners will be provided with defroster motor relays equipped with suppression resistors and installation instructions. Dealers will also replace the hcnc modules with upgraded modules. Owner notification is expected to begin during april 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact mci at 1‑800‑241‑2947.

Recall number 02V103000 · Recall details