2003 Mci E4500 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 2001-2015 J4500 and 1997-2013 102EL3/E4500 coaches equipped with a hydraulic rear axle (tag axle) steering system. The axle's alignment and low hydraulic pressure in the steering system may cause the steering system to lock, causing a loss of steering control at highway speeds.

Risk

Loss of steering control may increase the risk of a crash.

Remedy

MCI will inspect and repair axle alignment, as necessary, free of charge. MCI issued owners an interim notification on March 26, 2019. Owner notification letters were mailed on May 14, 2021. Owners may contact MCI customer service at 1‑800‑241‑2947. MCI's number for this recall is SB 469.

Recall number 19V027000 · 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 2001-2004 e4500, model year 2002-2006 e4500c, model year 2001-2005 j4500, and model year 2006 j4500c motor coaches equipped with se-gi passenger windows. The adhesive bond between the window glass and the aluminum window frame on the affected coaches may degrade.

Risk

If the window glass becomes partially or completely debonded from its frame, the window glass may detach and fall from the coach and cause personal injury or property damage.

Remedy

Dealers will inspect, test, and repair, as necessary, the se-gi window assemblies free of charge. The safety recall began on august 23, 2010. Owners may contact mci customer service at 1‑800‑241‑2947.

Recall number 10V373000 · Recall details

What is wrong

Mci is recalling certain model year 2008 and 2009 motor coaches, model j4500 manufactured between october 2007 and april 2009; 2009 motor coaches models d4000istv, d4005, d4500, and d4505 manufactured between january and july 2009; 2010 d4500 coaches manufactured between december 2008 and april 2009; 2009 e4500 coaches manufactured between january and april 2009; and one 2003 e4500 coach manufactured in october 2002. These vehicles may have been equipped with meritor wabco steering angle sensors (sas) which can develop internal friction between the sensor gears and the sensor housing as a result of external forces experienced on the vehicle including vibration. If developed friction is great enough, the driving tab of the sas can sheer as the driver turns the steering wheel.

Risk

With a broken sas driving tab, the electronic stability control (ESC) will not function properly, which could possibly result in a vehicle crash.

Remedy

Mci will notify owners and the vehicles will be repaired free of charge. The safety recall began on july 10, 2009. Owners may contact mci at 1‑800‑241‑2947.

Recall number 09V196000 · 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

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

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.

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