25V85300012/10/2025
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."
Model years in this history: 2020, 2019, 2018, 2017, 2016, 2015, 2014, 2013, 2012, 2011, 2010, 2009, 2008, 2007, 2006, 2005, 2004, 2003, 2002, 2001
Consequence and remedy
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.
24V07300002/07/2024
Motor Coach Industries (MCI) is recalling certain 2014-2018 D4000, 2013-2019 D4005, 2013-2023 D4500, 2013-2020 D4505, and 2021-2024 D45CRT coaches equipped with a Ricon wheelchair lift. The red beacon lighting on the Threshold Warning System (TWS) may not be bright enough. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 403, "Platform Lift Systems."
Model years in this history: 2023, 2022, 2021, 2020, 2019, 2018, 2017, 2016, 2015, 2014, 2013
Consequence and remedy
Consequence
Beacons that do not provide proper illumination may be less visible to wheelchair lift users, increasing the risk of injury.
Remedy
MCI will work with Ricon to replace the TWS kits, free of charge. Owner notification letters were mailed March 21, 2024. Owners may contact MCI customer service at 1-800-241-2947.
21V97100012/15/2021
Motor Coach Industries (MCI) is recalling certain 2019-2022 D4000 ISTV, D4500, 2021 D4000, D4520, 2020-2021 D4505, D4005, 2020-2022 D45CRTLE, and 2019-2021 J4500 vehicles equipped with certain Cummins X12 diesel engines. The fuel tubes between the fuel rail and the injectors for cylinders four, five, and six may fatigue and crack, which can result in a high pressure fuel leak.
Model years in this history: 2022, 2021, 2020, 2019
Consequence and remedy
Consequence
A high pressure fuel leak in the presence of an ignition source can increase the risk of a fire.
Remedy
On engines with 75 miles or less, Cummins dealers will install vibration isolators to the fuel tubes. Engines with more than 75 miles will receive new fuel tubes with vibration isolators. Repairs will be performed free of charge. Owner notification letters were mailed March 11, 2022. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is R21-028.
21V74800009/24/2021
Motor Coach Industries (MCI) is recalling certain 2018 D4000, 2018-2020 D4005, D4000ISTV, 2017-2020 D4500, D4505, 2018-2021 J3500, 2017-2021 J4500, 2020 D4520, and 2018-2021 D45CRTLE motorcoaches. The Main Distribution Panel (MDP) located within the battery compartment contains a circuit board that may fail.
Model years in this history: 2020, 2019, 2018, 2017
Consequence and remedy
Consequence
MDP circuit board failure can result in a fire or an unexpected vehicle shutdown, increasing the risk of a crash.
Remedy
MCI Service Centers will remove the MDP and install a new main disconnect and circuit breaker panel, free of charge. Owner notification letters were mailed November 12, 2021. Owners may contact MCI's customer service at 1-800-241-2947. MCI's number for this recall is R21-010.
21V36400005/18/2021
Motor Coach Industries (MCI) is recalling certain 2017-2018 D4000, 2017-2019 D4005, D4000ISTV, D4505, 2017-2020 D4500, J4500, 2018-2020 D45CRTLE, and 2018-2021 J3500 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.
Model years in this history: 2020, 2019, 2018, 2017
Consequence and remedy
Consequence
A fuel leak in the presence of an ignition source increases the risk of a fire.
Remedy
Dealers will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is R21-009.
20V35200006/12/2020
Motor Coach Industries (MCI) is recalling certain 2018-2020 D4000, D4005, D4500, D4505 and D45CRTLE buses manufactured with electric cooling fans (E-fan) for the radiator and charge air cooler, Borg Warner 55SI model dual alternator configuration (with a sense stud and wire), and Parker Vansco Multiplexing Module (VMM) Multiplex system. A build-up of debris, corrosion, and/or water flow could cause a high resistance path to ground for the sense stud on the back of the alternator and cause the alternator to produce excessive voltage output, which may exceed the threshold limit currently programmed in the VMM and result in a loss of engine power and vehicle shutdown.
Model years in this history: 2020, 2019, 2018
Consequence and remedy
Consequence
If the engine shuts down or loses power while the vehicle is in motion, this may increase the risk of a crash.
Remedy
MCI will notify the affected owners, and dealers will install a new application code in the Parker VMM multiplex modules increasing the overvoltage threshold limit, free of charge. The recall began July 23, 2020. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is SB 479.
20V24200004/29/2020
Motor Coach Industries (MCI) is recalling certain 2015-2016 D4000, 2015-2020 D4500 and D4505, 2016-2020 J4500, 2018 J3500, and 2017 D4005 buses. The seat belts may not extend from the retracted position, rendering the seat belt unusable. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standards (FMVSS) number 208, "Occupant Crash Protection," and number 209, "Seat Belt Assemblies."
Model years in this history: 2020, 2019, 2018, 2017, 2016, 2015
Consequence and remedy
Consequence
Inability to use the seat belt may increase the risk of injury in the event of a crash.
Remedy
MCI will notify the affected owners, and dealers will inspect and replace the seat belts, as necessary, free of charge. MCI issued owners an interim notification June 26, 2020. The recall began January 13, 2021. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is SB 482.
19V92400012/27/2019
Motor Coach Industries (MCI) is recalling certain 2018-2020 D4505 and D4500 coaches equipped with an optional steerable tag axle. The tag axle mounting block clamps that retain the tie rod to obtain the forward steer orientation may slip, resulting in the tag axle being out of alignment.
Model years in this history: 2020, 2019, 2018
Consequence and remedy
Consequence
If the tag axle becomes misaligned with the front of the vehicle, the rear of the vehicle may strike other vehicles or pedestrians, increasing the risk of a crash or injury.
Remedy
MCI will notify owners, and dealers will replace the block clamps and retorque the fasteners, free of charge. The recall began February 19, 2020. Owners may contact MCI customer service at 1-800-241-2947.
18V30900005/13/2018
Motor Coach Industries (MCI) is recalling certain 2011-2016 D4500, D4505, D4000, D4005, and D4000 ISTV motor coaches equipped with ISX engines. Due to vibrations, the exhaust bellow pipes develop a hole.
Model years in this history: 2016, 2015, 2014, 2013, 2012, 2011
Consequence and remedy
Consequence
If the pipe develops a hole, during a regeneration cycle, hot exhaust gases may leak out, increasing the risk of a fire.
Remedy
MCI will notify owners, and dealers will replace the bellows pipe assembly with an improved part, free of charge. The recall began July 10, 2018. Owners may contact MCI customer service at 1-800-241-2947.
17V33700005/24/2017
Motor Coach Industries (MCI) is recalling certain 2011-2012 MCI D4000, D4005, D4500 and D4505 coaches equipped with Cummins ISX 12 liter engines. The vehicles may have an incorrectly installed exhaust bellow pipe, resulting in a bend in the pipe which can cause its premature failure.
Model years in this history: 2012, 2011
Consequence and remedy
Consequence
If the pipe fails and a diesel regeneration cycle occurs, the hot exhaust gases will increase the risk of a fire.
Remedy
MCI will notify owners and dealers will inspect and replace any deformed or failed bellow pipes if necessary, free of charge. The recall began on June 15, 2017. Owners may contact Motor Industries at 1-800-241-2947. MCI's number for this recall is SB 397B.
16V02000001/20/2016
Motor Coach Industries (MCI) is recalling certain model year 2011-2013 and 2015 J4500 coaches manufactured November 18, 2011, to July 10, 2015, 2011-2012 and 2014-2015 D4000 coaches manufactured manufactured September 24, 2010, to September 5, 2015, 2011-2013 and 2015-2016 D4005 coaches manufactured January 17, 2011, to November 23, 2015, 2012-2014 and 2016 D4000ISTV coaches manufactured July 18, 2012, to December 2, 2015, 2010-2016 D4500 coaches manufactured April 15, 2010, to December 18, 2015 and 2011-2016 D4505 coaches manufactured December 15, 2010, to December 4, 2015. The affected buses are equipped with certain Recaro Ergo-M Commercial Bus Driver Seats that have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.
Model years in this history: 2016, 2015, 2014, 2013, 2012, 2011, 2010
Consequence and remedy
Consequence
If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.
Remedy
MCI will notify owners and dealers will inspect the seats and determined if welds are missing. Any J-Bracket that is missing welds will be removed and replaced, free of charge. The recall began on February 15, 2016. Owners may contact MCI at 1-800-241-2947. MCI's number for this recall is SB 431.
15V83700012/14/2015
Motor Coach Industries (MCI) is recalling certain model year 2015 D4500 motor coaches manufactured January 23, 2015, to May 1, 2015, and D4505 motor coaches manufactured May 12, 2015, to May 13, 2015. The affected coaches have drive axles that may be missing welds on the hanger brackets, allowing the hanger bracket to separate from the axle housing.
Model years in this history: 2015
Consequence and remedy
Consequence
If the bracket separates from the axle housing, vehicle control may be affected, increasing the risk of a crash.
Remedy
MCI will notify owners, and dealers will inspect the coaches and replace the affected axles, free of charge. The recall began on January 4, 2016. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is SB 429.
15V58000009/21/2015
Motor Coach Industries, Inc. (MCI) is recalling certain model year 2015 D4000 vehicles manufactured June 8, 2015, to July 20, 2015, D4005 vehicles manufactured March 18, 2015, to July 10, 2015, D4500 vehicles manufactured December 19, 2014, to July 20, 2015, and D4505 vehicles manufactured December 18, 2014, to July 15, 2015. In the affected vehicles, the fuse block assembly for the heating, ventilation and air conditioning motors in the battery compartment may have been assembled incorrectly.
Model years in this history: 2015
Consequence and remedy
Consequence
The incorrectly assembled fuse block may not protect the circuit and the connections may arc, increasing the risk of a fire.
Remedy
MCI will notify owners, and dealers will replace the fuse block assembly, free of charge. The recall began on November 2, 2015. Owners may contact MCI customer service at 1-800-241-2947.
15V38900006/19/2015
Motor Coach Industries (MCI) is recalling certain model year 2014 D4500 vehicles manufactured December 19, 2013, to April 14, 2014, 2013-2014 D4505 vehicles manufactured February 1, 2013, to April 22, 2014, and 2013-2015 J4500 vehicles manufactured November 26, 2013, to May 22, 2015. The affected motorcoaches are equipped with hub carriers that may have areas of porosity which could result in the hub carrier leaking oil or cracking.
Model years in this history: 2014
Consequence and remedy
Consequence
Cracks in the hub may result in hub failure, which could cause a loss of vehicle control, increasing the risk of a crash.
Remedy
MCI will notify owners, and dealers will begin a routine inspection process to identify any hub carrier leaks. When parts become available, the affected hub carriers will be replaced, free of charge. The recall began on August 4, 2015. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is SB 425.
15V27600005/12/2015
Motor Coach Industries (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured November 12, 2011, to July 11, 2012, and 2014-2015 D4500 motorcoaches manufactured July 4, 2014, to April 30, 2015. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.
Model years in this history: 2015, 2014
Consequence and remedy
Consequence
If the engine oil comes into contact with a hot surface, it can increase the risk of a vehicle fire.
Remedy
MCI will notify owners, and Cummins service centers will administer the repairs which include securing the ends of the 90-degree elbow and reprogramming the electronic control module (ECM) with software that can adjust the engine output under misfire conditions to limit crankcase pressures. These repairs will be performed free of charge. The recall began on June 18, 2015. Owners may contact MCI customer service at 1-800-241-2947 or Cummins Inc. at 1-800-343-7357. MCI's number for this recall is SB 423.
15V18400003/30/2015
Motor Coach Industries (MCI) is recalling certain model year 2014 J4500 and model year 2015 D4000ISTV, D4005, D4500, and D4505 motor coaches manufactured August 26, 2014, to December 3, 2014. The affected motor coaches have front and steerable tag axles whose tie rod nuts may be improperly torqued.
Model years in this history: 2015, 2014
Consequence and remedy
Consequence
If the tie rod nuts are not properly torqued, the tie rod may not be adequately secured, resulting in a loss of vehicle control and increasing the risk of a crash.
Remedy
MCI will notify owners, and dealers will inspect the tie rod nut torque, replacing the parts as necessary, free of charge. The recall began on April 15, 2015. Owners may contact MCI customer service at 1-800-241-2947.
14V32900006/16/2014
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.
Model years in this history: 2011, 2010, 2009
Consequence and remedy
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.
14V37000006/09/2014
Motor Coach Industries, Inc. (MCI) is recalling certain model year 2014 D4000, D4005, D4000ISTV, D4500, D4505, and J4500 motor coaches manufactured July 2013 to April 2014. The multiplex electrical systems controller may unintentionally turn off the vehicle's headlights while the vehicle is in gear.
Model years in this history: 2014
Consequence and remedy
Consequence
If the headlights turn off while the vehicle is in operation, the driver's visibility may be reduced, increasing the risk of a crash.
Remedy
MCI will notify owners, and dealers will update the multiplex controller software, free of charge. The recall began in July 2014. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is 413.
13V49800010/17/2013
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.
Model years in this history: 2011, 2010, 2009, 2008, 2007, 2006, 2005, 2004, 2003, 2002, 2001
Consequence and remedy
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.
13V14200004/16/2013
Motor Coach Industries (MCI) is recalling certain model year 2012-2013 D4000, D4000ISTV, D4005, D4500, and D4505 motorcoaches manufactured from May 2012 through December 2012 and equipped with a Cummins ISX EPA 2010 engine. In the affected buses, the bellows pipe in the exhaust system may have been incorrectly assembled, which could result in a failure of the pipe during operation.
Model years in this history: 2013, 2012
Consequence and remedy
Consequence
During a regeneration process to clean exhaust emissions, if the bellows pipe has failed, the hot exhaust gases may not be contained, resulting in a fire.
Remedy
MCI will notify owners and dealers will inspect and replace the bellows pipes, as necessary, free of charge. The recall began on April 29, 2013. Customers may contact MCI at 1-847-285-2000.
12V25000005/31/2012
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.
Model years in this history: 2011, 2010, 2009
Consequence and remedy
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.
12V08600003/05/2012
MOTOR COACH INDUSTRIES, INC (MCI) IS RECALLING CERTAIN MODEL YEAR 2012 D4505, D4500, AND D4000ISTV MOTOR COACHES, EQUIPPED WITH A SEDAN STYLE ENTRANCE DOOR AND AN ACTIA MULTIPLEX SYSTEM. THIRTY MINUTES AFTER THE PARK BRAKE IS SET AND THE IGNITION IS TURNED OFF, THE ENTRANCE DOOR WILL CLOSE WITHOUT WARNING.
Model years in this history: 2012
Consequence and remedy
Consequence
THE ENTRANCE DOOR WILL CLOSE WITHOUT WARNING, INCREASING THE RISK OF PERSONAL INJURY TO PEOPLE ENTERING OR EXITING THE BUS.
Remedy
MCI WILL NOTIFY OWNERS, AND REMEDY THE AFFECTED COACHES BY REPROGRAMMING THE MULTIPLEX SYSTEM, FREE OF CHARGE. THE RECALL BEGAN ON APRIL 11, 2012. OWNERS MAY CONTACT MCI AT 1-800-241-2947.
11V52400010/26/2011
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.
Model years in this history: 2012, 2011, 2010, 2009, 2008, 2007
Consequence and remedy
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.
11V01600001/12/2011
MCI IS RECALLING CERTAIN MODEL YEAR 2010-2011 D4500, D4505, AND D4000 MOTOR COACHES. THE AFFECTED PULLEY COVERS MAY LACK CERTAIN WELDS REQUIRED TO KEEP THE COVERS ATTACHED TO THE COACH STRUCTURE.
Model years in this history: 2011, 2010
Consequence and remedy
Consequence
THE COVER WILL EVENTUALLY FAIL AS A RESULT OF FATIGUE, AND THE COVER MAY BECOME DETACHED FROM THE COACH AND FALL AND STRIKE A PERSON OR OBJECT, RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.
Remedy
MCI WILL INSPECT AND REPLACE AS NECESSARY THE IDLER PULLEY COVERS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON FEBRUARY 10, 2011. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.
