2007 Mci D4505 problems

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 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 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 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

Mci is recalling 103 my 2005-2008 d4500 and d4505 coaches equipped with detroit diesel series 60 engines and a zf transmission. Customers may experience a possible interference between the drive shaft u-joint bearing cap bolts and the tag axle center beam assembly.

Risk

Interference between the bearing cap bolts and the axle center beam assembly could cause the bearing cap bolts to shear, freeing the bearings and possibly releasing the drive shaft, increasing the risk of vehicle damage or a crash.

Remedy

Dealers will install a tag axle suspension spacer kit and an spl250 driveshaft retrofit kit to limit the suspension travel and reduce the swing diameter of the driveshaft thereby increasing the clearance and eliminating any possible interference. The recall began on february 25, 2009. Owners may contact mci at 1800-241-2947.

Recall number 09V041000 · Recall details

What is wrong

Mci is recalling 1,893 my 2002-2008 d model and my 2001-2008 e and j4500 motor coaches equipped with zf transmissions. There is a potential for the shift selector to malfunction as a result of a cell phone or radio being placed in close proximity to the shifter control pad.

Risk

When this happens, the shift selector may move into reverse without driver knowledge increasing the risk of a crash.

Remedy

Mci is working with zf and has created a software update that protects against the potential for transient analog or digital signal interference. The recall is expected to begin during november 2008. .owners may contact mci at 1‑800‑333‑0371 and zf at 1‑734‑416‑6200.

Recall number 08V603000 · Recall details

What is wrong

Mci is recalling 185 my 2006-2007 d4005 and d4505 motor coaches equipped with dura side body egress windows. These coaches fail to comply with the requirements of federal motor vehicle safety standard no. 217, 'bus emergency exits and window retention and release.' the windows were produced with inconsistent priming on the primary and secondary bond lines.

Risk

The purpose of this standard is to minimize the likelihood of occupants being thrown from the bus and to provide a means of readily accessible emergency egress.

Remedy

Mci will notify owners instructing them to inspect the windows for signs of water leak, wind noise, or visible partial de-bonding. Windows showing these signs will be replaced free of charge by dura (please see 07e042). The recall began on august 27, 2007. Owners can contact dura at 1‑248‑844‑1615 or mci at 1‑800‑241‑2947.

Recall number 08V386000 · Recall details

What is wrong

On certain d series motor coaches, there could be a possible interference between the drive shaft mounting hardware and the tag axle structure.

Risk

The bearing cap bolts could shear, freeing the bearings, and possibly releasing the drive shaft, increasing the risk of a crash.

Remedy

Shims will be installed above the tag axle air spring mounting brackets to limit the suspension travel. The recall is expected to begin during january 2007. Owners may contact mci at 1‑800‑241‑2947.

Recall number 06V480000 · 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

ODI opened this investigation upon learning of two incidents where the wheel chair assembly broke through the side door while the motor coach was being operated. Both incidents resulted in property damage to parked vehicles.After further review, MCI decided to conduct a safety recall to resolve this issue. MCI will provide parts and labor to install a Ricon-designed retrofit kit that includes a spring-loaded lock mechanism. The additional lock mechanism will prevent unintended wheel chair lift deployment regardless of the cause. The population includes 1995 through 2009 D4000's, 1997 through 2010 D4500's, and 2005 through 2010 D4505 models. This resolves all issues concerning this investigation. This investigation is closed.

PE10001