Mci D4000 Recalls & Complaints by Model Year
NHTSA lists 29 safety recalls and 0 owner complaints across 25 model years of the Mci D4000 (1997–2021).
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All Mci D4000 recalls (29)
Every NHTSA safety campaign that lists a Mci D4000, most recent first, with the model years each one covers.
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Door (structure) and glass, side/rear (visibility)
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…
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.
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Wheelchair lift/ramp (equipment adaptive/mobility)
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…
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.
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Fuel rail (fuel system)
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…
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…
Model years: 2021
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Electrical system
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.
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…
Model years: 2018
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Fuel rail (fuel system)
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.
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…
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Alternator/generator/regulator (electrical system)
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.…
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.…
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Seat belts
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…
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…
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Manifold/header/muffler/tail pipe (engine and engine cooling) and exhaust system (engine and engine cooling)
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.
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.
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Exhaust system (engine and engine cooling)
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.
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.…
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Seats
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,…
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.…
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Fuses and circuit breakers (electrical system)
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…
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.
Model years: 2015
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Engine (engine and engine cooling)
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…
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…
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Interior lighting and fuses and circuit breakers (electrical system)
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…
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:…
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Headlights (exterior lighting)
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.
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…
Model years: 2014
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Engine (engine and engine cooling)
Motor Coach Industries, Inc. (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured March 2011 through July 2012 and equipped with certain Cummins Westport model ISL G. Condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold…
Remedy: MCI will notify owners, and authorized Cummins service facilities will upload a new ECM calibration, free of charge. The recallbegan on April 16, 2014. Customers may contact MCI at 1-847-285-2090 or Cummins Inc. at…
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Electrical system
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…
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.
Model years: 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011
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Exhaust system (engine and engine cooling)
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…
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.
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Interior lighting
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.
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.
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Electronic stability control (esc)
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…
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.
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Fan (engine and engine cooling)
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.
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.
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Axle assembly (power train)
Mci is recalling certain model year 2010 d4000, d4005, d4500, d4505, e4500, and j4500 model motor coaches manufactured from september 2009 through may 2010, equipped with arvinmeritor front and tag axle assemblies. The suspect axles may have had improper torque applied to the hub/rotor/wheel adapter bolts during the assembly process.…
Remedy: Mci will notify owners and dealers will repair the motor coaches free of charge. The safety recall began on may 28, 2010. Owners may contact mci at 1-800-241-2947.
Model years: 2010
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Equipment adaptive/mobility
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,…
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…
Model years: 2009
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Equipment adaptive/mobility
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,…
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…
Model years: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
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Alternator/generator/regulator (electrical system)
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.
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.
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Interior lighting
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.
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…
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12v/24v/48v battery (electrical system)
On certain motor coaches, the boost connector housing can fail over time, exposing the positive and negative terminals.
Remedy: Customers are being advised to remove the boost connector and discard it. Customers will be offered a new design boost connector as an alternative at no cost. The recall began on january 2, 2007. Owners may contact mci…
Model years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
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Defroster/defogger/hvac system (visibility)
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…
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.
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Diesel (engine and engine cooling)
On certain motor coaches equipped with detroit diesel series 60 engines, the turbocharger compressors can 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…
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Electrical system: wiring
On certain motor coaches that have multiplex systems, when the coach's defroster motor is activated, certain high speed cell net controllers (hcnc) may lock up.
Remedy: Owners will be provided with defroster motor relays equipped with suppression resistors and installation instructions. Dealers will also replace the hcnc modules with upgraded modules. Owner notification is expected to…
Model years: 2002
Other Mci models
- J45003 complaints
- 102D32 complaints
- 102DL32 complaints
- D45002 complaints
- E45002 complaints
- D4500/102DL31 complaints
- D45051 complaints
- MC121 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.