2003 Mci J4500: complaints, problems and recalls

COACH SIDE GLASS IS BOWING (CHANGING SHAPE) AND DE-BONDING. ALL GLASS ON COACH SAYS "SI-GI", WHICH IS THE DEFECTIVE GLASS SUBJECT TO A RECALL (NHTSA RECALL #10V373000). CONTACTED MCI IN 2015 AFTER 1 OF THE PIECES OF GLASS ACTUALLY ALMOST FELL OUT. MFGR REFUSES TO HONOR WARRANTY BECAUSE THEY SHIPPED REPLACEMENT GLASS TO THE PREVIOUS VEHICLE OWNER FOR THEM TO INSTALL THEMSELVES. DEFECTIVE SI-GI GLASS STILL IN THE COACH. MFGR PRACTICE OF SHIPPING REPLACEMENT GLASS TO OWNERS IS A VERY BAD IDEA. MFGR DOES NOT ACTUALLY VERIFY THAT THE WORK WAS COMPLE…

Owner-reported narrative. Look up ODI 10981434 at NHTSA ↗

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: 2006-07-06 (July 6, 2006)

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.

Consequence: 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.

Reported: 2008-11-21 (November 21, 2008)

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.

Consequence: 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.

Reported: 2010-04-06 (April 6, 2010)

MCI IS RECALLING CERTAIN MODEL YEAR 1999-2001, 2007-2011 E4500 AND MODEL YEAR 2001-2011 J4500 COACHES EQUIPPED WITH DOGA WINDSHIELD MOTORS. THE WINDSHIELD WIPER MOTOR MAY FAIL TO OPERATE PROPERLY WHILE THE WIPER SYSTEM IS FUNCTIONING. IF THIS OCCURS, THE WINDSHIELD WIPERS MAY OPERATE INTERMITTENTLY, OPERATE AT A SINGLE SPEED ONLY, OR COMPLETELY STOP OPERATING.

Consequence: IF THE WINDSHIELD WIPERS STOP FUNCTIONING, THE DRIVER'S CLEAR FIELD OF VIEW MAY BE REDUCED INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL FURNISH THE PARTS AND LABOR REQUIRED TO IMPLEMENT THE DOGA-RECOMMENDED REMEDIES ON THE AFFECTED COACHES. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING JULY 2010. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.

Reported: 2010-08-11 (August 11, 2010)

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.

Consequence: 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.

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: 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: 2019-01-07 (January 7, 2019)

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.

Consequence: 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.

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.