2002 Mci G4500: complaints, problems and recalls

Reported: 2002-10-30 (October 30, 2002)

ON CERTAIN MOTOR COACHES, THE ELECTRICAL CABLE ATTACHED TO THE B+ STUD, WHICH IS LOCATED ON THE ENGINE CRADLE AND FOUND IN THE CURBSIDE ENGINE COMPARTMENT, MAY HAVE BEEN POSITIONED SO AS TO ALLOW THE CABLE TO RUB AGAINST THE GROUND STUD.

Consequence: A SHORT CIRCUIT COULD OCCUR AND RESULT IN A FIRE.

Remedy: OWNERS WILL BE PROVIDED REMEDY INSTRUCTIONS. THE RECALL BEGAN ON OCTOBER 25, 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: 2003-10-22 (October 22, 2003)

ON CERTAIN MOTOR COACHES EQUIPPED WITH TAG AXLE SWING ARM ASSEMBLIES, INSUFFICIENT WELD METAL AND/OR WELD PENETRATION ON THE TAG AXLE SWING ARM WHERE IT MEETS THE PIVOT SPINDLE TUBE COULD LEAD TO STRESS AND FATIGUE CRACKS.

Consequence: THIS COULD RESULT IN COMPLETE SEPARATION OF THE TAG AXLE FROM THE COACH, INCREASING THE RISK OF A CRASH.

Remedy: MCI WILL INSPECT AND REPAIR OR REPLACE THE ASSEMBLIES. THE RECALL BEGAN ON OCTOBER 20, 2003. 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 1-800-321-2947.

Reported: 2004-07-07 (July 7, 2004)

ON CERTAIN MOTOR COACHES, THE FRONT LOWER RADIUS ROD MOUNTING BRACKET COMPONENTS MAY NOT HAVE BEEN WELDED SUFFICIENTLY.

Consequence: THESE WELDS MAY CRACK, ALLOWING MOVEMENT AND POTENTIAL SEPARATION OF THE RADIUS ROD MOUNTING BRACKET, WHICH COULD RESULT IN A CRASH.

Remedy: OWNERS HAVE BEEN PROVIDED WITH REPAIR INSTRUCTIONS. THE RECALL BEGAN ON JULY 1, 2004. OWNERS 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: 2006-11-29 (November 29, 2006)

ON CERTAIN G4500 MOTOR COACHES, THE TAG AXLE SWING ARM CAN BREAK AWAY.

Consequence: IF THE TAG AXLE SWING ARM CRACKS AND REMAINS UNDETECTED, THE CRACKS CAN SPREAD AND POTENTIALLY RESULT IN A PARTIAL OR TOTAL SEPARATION OF THE TAG AXLE ASSEMBLY FROM THE COACH, INCREASING THE RISK OF A CRASH.

Remedy: PLEASE NOTE THAT THIS CAMPAIGN HAS BEEN SUPERSEDED BY 08V121.

Reported: 2007-03-05 (March 5, 2007)

ON CERTAIN MOTOR COACHES, A WELD JOINING A GUSSET SUPPORT FROM THE FRONT BOGIE LEG TO THE STEERING BOX MOUNTING PLATE CAN CRACK.

Consequence: THIS CAN ALLOW ADDITIONAL MOVEMENT OF THE MOUNTING PLATE IN DRY STEER APPLICATIONS AND AT THE EXTREME OUTWARD STEERING POSITIONS INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSTALL AN ADDITIONAL GUSSET TO THESE ASSEMBLIES AND REWELD AS REQUIRED. THE RECALL BEGAN ON MARCH 23, 2007. OWNERS MAY CONTACT MOTOR COACH AT 1-800-241-2947.

Reported: 2008-03-18 (March 18, 2008)

MCI IS RECALLING 542 MY 2000-2004 G4100 AND G4500 MOTOR COACHES. CERTAIN REWORKED TAG AXLE ARM ASSEMBLIES HAD BEEN IDENTIFIED WITH NEW CRACKS FORMING. SOME OF THE TAG AXLE ARM ASSEMBLIES THAT HAD PREVIOUSLY BEEN REPAIRED DURING RECALLS 03V-411 OR 06V458 MAY HAVE BEEN REPAIRED WITH UNIDENTIFIED MICRO FRACTURES AND/OR INSUFFICIENT WELD PENETRATION.

Consequence: IF THE TAG AXLE SWING ARM CRACKS AND REMAINS UNDETECTED, THE CRACKS CAN SPREAD AND POTENTIALLY RESULT IN A PARTIAL OR TOTAL SEPARATION OF THE TAG AXLE ASSEMBLY FROM THE COACH, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL RE-INSPECT AND IF CRACKS ARE IDENTIFIED OR INCORRECT WELDS IN THE PREVIOUSLY REPAIRED AREAS, BOTH RIGHT AND LEFT TAG ARM ASSEMBLIES WILL BE REPLACED. IF NO PROBLEMS ARE IDENTIFIED, DEALERS WILL REINSTALL THE EXISTING TAG AXLE ARM ASSEMBLIES WITH NEW HARDWARE FREE OF CHARGE. PLEASE NOTE THAT THIS CAMPAIGN SUPERSEDES MCI'S PREVIOUS RECALLS (PLEASE SEE 03V411 AND 06V458). THE RECALL BEGAN ON MARCH 18, 2008. OWNER MAY CONTACT MOTOR COACH AT 1-800-241-2947.

Reported: 2009-09-02 (September 2, 2009)

MCI IS RECALLING MODEL YEAR 2001-2004 G4500 MOTOR COACHES EQUIPPED WITH WHEELCHAIR LIFTS. IF THE UPPER WHEELCHAIR DOOR OPENS DUE TO A MALFUNCTION OF THE DOOR'S LATCHES, THERE IS A TELLTALE LIGHT IN THE INSTRUMENT PANEL THAT ILLUMINATES TO ALERT THE DRIVER THAT THE UPPER WHEELCHAIR DOOR IS NOT FULLY LATCHED AND CLOSED, HOWEVER THE DRIVER COULD FAIL TO NOTICE THAT THIS LIGHT IS ILLUMINATED.

Consequence: THIS COULD RESULT IN THE WHEELCHAIR DOOR SLIDING OPEN WITHOUT FURTHER WARNING AND EXPOSE PASSENGERS TO THE RISK OF FALLING FROM THE COACH WHILE THE VEHICLE IS IN MOTION.

Remedy: DEALERS WILL INSTALL AN AUDIBLE ALARM IN THE DRIVER'S AREA TO PROVIDE AN ADDITIONAL ALERT IN THE EVENT THE DOOR IS NOT FULLY CLOSED AND LATCHED, AND WILL REINFORCE THE UPPER LATCH TO IMPROVE ITS DURABILITY. THE RECALL BEGAN ON SEPTEMBER 4, 2009. OWNERS MAY CONTACT MCI CUSTOMER SERVICE LINE AT 1-800-241-2947.