2002 Mci D4500: complaints, problems and recalls

DEFECTIVE AIR BRAKE EQUIPMENT ON MCI D4500 BUSES.*MR IF THERE IS LESS THAN 90 PCI IN THE AIR SYSTEM THERE IS AN AUDIBLE BUZZER AND THE HAZARD LIGHT ILLUMINATES INDICATING LOW AIR. THE EMERGENCY BRAKE SYSTEM DOES NOT WORK UNTIL THE AIR PRESSURE IS ALMOST "0" ON THE MANOMETER ON THE DASHBOARD. *BF *NM

Owner-reported narrative. Look up ODI 10118893 at NHTSA ↗

Reported: 2002-04-04 (April 4, 2002)

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.

Consequence: 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.

Reported: 2006-04-27 (April 27, 2006)

ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.

Consequence: 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.

Reported: 2006-12-19 (December 19, 2006)

ON CERTAIN MOTOR COACHES, THE BOOST CONNECTOR HOUSING CAN FAIL OVER TIME, EXPOSING THE POSITIVE AND NEGATIVE TERMINALS.

Consequence: 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.

Reported: 2009-11-03 (November 3, 2009)

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.

Consequence: 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.

Reported: 2010-03-09 (March 9, 2010)

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.

Consequence: 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.

Reported: 2013-10-17 (October 17, 2013)

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.

Consequence: 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.

Reported: 2025-12-10 (December 10, 2025)

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."

Consequence: 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.