2009 Mci J4500: complaints, problems and recalls

Reported: 2009-04-08 (April 8, 2009)

MCI IS RECALLING 316 MY 2008-2009 J4500 COACH VEHICLES. THESE VEHICLES MAY CONTAIN A DISTORTED VALVE IN THE AUTOMATIC TRACTION CONTROL (ATC) AND/OR ELECTRONIC STABILITY CONTROL (ESC) SYSTEMS. UNDER CERTAIN CONDITIONS, THE VALVE MAY STICK IN THE OPEN POSITION AND CAUSE FULL SERVICE BRAKE PRESSURE TO BE APPLIED TO EITHER THE FRONT AXLE BRAKES OR THE DRIVE AND TAG AXLE BRAKES, DEPENDING ON WHETHER THE DISTORTED VALVE IS A FRONT OR REAR VALVE.

Consequence: IN THE EVENT THE VALVE STICKS IN AN OPEN POSITION AND CAUSES FULL SERVICE BRAKE PRESSURE TO BE APPLIED, A VEHICLE MAY EXPERIENCE BRAKE LOCK-UP ONCE THE VEHICLE SLOWS TO 5 MPH, THEREBY INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT AND REPLACE THE ATC VALVES FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING MAY 2009. OWNERS MAY CONTACT MCI AT 847-285-2000.

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: 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: 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: 2012-03-30 (March 30, 2012)

MOTOR COACH INDUSTRIES, INC (MCI) IS RECALLING CERTAIN MODEL YEAR 2009-2012 J MOTOR COACHES. DUE TO INADEQUATE BONDING, THE TRANSOM WINDOWS (THE REAR-MOST WINDOWS ON EACH SIDE), MAY DETACH FROM THE COACH.

Consequence: A TRANSOM WINDOW MAY DETACH WITHOUT WARNING, INCREASING THE RISK OF PERSONAL INJURY OR PROPERTY DAMAGE.

Remedy: MCI WILL NOTIFY OWNERS, AND DEALERS WILL INSTALL MECHANICAL RETENTION CLIPS ON THE TRANSOM WINDOWS, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JUNE 5, 2012. OWNERS MAY CONTACT MCI 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: 2014-04-04 (April 4, 2014)

Motor Coach Industries (MCI) is recalling certain model year 2009-2014 E4500 and J4500 motorcoaches manufactured October 2008 through October 2013, and equipped with passenger seats with 3-point seat belts. The seat track for the second row passenger seats may be missing a weld at the end of the seat track where it enters the frame structure.

Consequence: In the event of a crash, the seat may detach from its floor mounting, increasing the risk of injury to the occupant.

Remedy: MCI will notify owners, and dealers will modify the seat anchorage, free of charge. The recall began on May 9, 2014. Owners may contact MCI at 1-800-241-2947. MCI's number for this recall is 408.

Reported: 2015-03-30 (March 30, 2015)

Motor Coach Industries (MCI) is recalling certain model year 2007-2010 MCI E4500 and J4500 motor coaches manufactured November 21, 2006, to August 27, 2009, and equipped with certain Recaro Automotive Seating Ergo M bus driver seats. The affected seats were manufactured in a way that the tether bar may push into the retractor panel door and potentially interfere with the seat belt locking mechanism.

Consequence: If the seat belt locking mechanism does not function as intended, the bus driver may not be properly restrained, increasing the risk of personal injury in the event of a crash.

Remedy: MCI will notify owners , and dealers will inspect and retrofit the seats free of charge. The recall began on May 14, 2015. Owners may contact MCI customer service at 1-800-241-2947.

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: 2021-09-23 (September 23, 2021)

Motor Coach Industries (MCI) is recalling certain 2005-2009 E4500 and 2005-2012 J4500 motorcoaches equipped with Ricon Baylift Wheelchair Lifts. When the lift's outer barrier is fully deployed, it may not withstand a sufficient amount of force, which could cause it to fail. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 403, "Platform Lift Systems," and number 404, "Platform lift installations."

Consequence: In the event that a mobility device pushes into the outer barrier, the barrier may fail, increasing the risk of injury for the lift occupant.

Remedy: Ricon will reinforce the outer barrier with additional supports, free of charge. Owner notification letters were mailed on October 18, 2021. Owners may contact the Ricon's Customer Service at (800) 322-2884, or email Ricon’s Recall Coordinator, at admin21e068@Wabtec.com or by locating the nearest Ricon servicing dealer using the locator on the Ricon website – www.riconcorp.com. Owners may also contact MCI's customer service at 1-800-241-2947. MCI's number for this recall is R21-024.

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.