2017 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 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 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 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

During the review of Motor Coach Industries (MCI) Early Warning Reporting (EWR) 2016 Q4 data, field reports were identified that described fires on 2 buses from different regions of the country.These fires were alleged to have occurred as a result of a loose clamp allowing the tailpipe to separate from the exhaust after treatment assembly.During exhaust after treatment regeneration high temperature gases were directed at the plastic rear bumper.Prior to the fires, there were no indications (such as soot trails) that the clamps were loose.When contacted, the fleet maintenance manager stated all maintenance schedules and DOT inspections had been performed without a failure citation of the exhaust systems. MCI addressed the issue by installing additional brackets to the pipe on all the other buses in the fleet ensuring the tailpipe stayed intact should the clamp lose torque.In correspondence with another fleet using the same style bus, the fleet safety manager described having loose clamps resulting in fires.The MCI fix for the second fleet was to install a shield at the rear bumper to deflect the high temperature exhaust gases in the event of the tailpipe separated from the exhaust after treatment system.This fix was different from the first fleet.During review of communications submitted in March 2017, the Office of Defects Investigation (ODI) identified MCI Service Bulletin No. 309 regarding a maintenance procedure of the exhaust system Torca Accuseal clamp.This bulletin instructed that a new clamp must be utilized after any service or maintenance is performed in which the existing clamp was loosened or removed.ODI requested further information on this bulletin and received warranty claims showing loose tailpipes.MCI has taken the position that fires at the clamp location were due to improper maintenance by the fleets.After analysis of data, provided by MCI to ODI in response to an information request letter, ODI found there was not an increasing number (claim rate of 1.1%) of failures and fires even with portions of the fleet having over seven years in service.The 4 fires identified were from 2 fleets.ODI contacted the fleets with fire incidents and was informed that one of the two buses involved in the fire incidents was sold in 2016 and other fleet does not have maintenance records since they only keep records for one year.ODI is closing the investigation as no actionable trend has been identified.This investigation is closed. Further use of agency resources does not appear to be warranted. The closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist. The agency reserves the right to take further action if warranted by the circumstances.

PE17008