2009 Mci D4500: complaints, problems and recalls

Reported: 2009-06-01 (June 1, 2009)

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.

Consequence: 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.

Reported: 2009-09-09 (September 9, 2009)

MCI IS RECALLING MODEL YEAR 2009 D4500/4505 COACHES EQUIPPED WITH THE MERITOR FH 946 14,000 LB RATED STEERABLE TAG AXLE. DUE TO INSUFFICIENT CLAMPING FORCE OF THE CYLINDER LOCK PLATE, IT MAY MOVE FROM ITS NORMAL SET POSITION, WHICH IN TURN COULD RESULT IN THE TAG AXLE NOT AUTOMATICALLY LOCKING, OR LOCKING WITH THE WHEELS NOT IN A STRAIGHT AHEAD POSITION.

Consequence: IF THE TAG AXLE DOES NOT LOCK ABOVE 20 MPH, THERE IS A LOSS OF LATERAL FORCE CONTROL OF THE TAG AXLE THAT CAN AFFECT THE STEERING OF THE VEHICLE. ALSO DURING A TURN THE REAR OF THE VEHICLE WILL SWING FURTHER OUT IN THE OPPOSITE DIRECTION OF THE TURN AND COULD RESULT IN THE COACH STRIKING ANOTHER VEHICLE INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL PROVIDE REPLACEMENT CLAMPS THAT DO NOT HAVE PAINT ON THE CLAMPING SURFACES. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2009. OWNERS MAY CONTACT MCI CUSTOMER SERVICE LINE 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: 2009-11-18 (November 18, 2009)

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.

Consequence: 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.

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: 2010-03-24 (March 24, 2010)

MCI HAS NOTIFIED NHTSA 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.

Consequence: 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 WWW.DMATA@WABTEC.COM.

Reported: 2011-10-26 (October 26, 2011)

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.

Consequence: 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.

Reported: 2012-05-31 (May 31, 2012)

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.

Consequence: 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.

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: 2014-06-16 (June 16, 2014)

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.

Consequence: 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.

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.