2010 MCI D4000

6 recalls — 0 complaints — 11 TSBs

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

Defect Description

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... Read more

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 t... Read more

312 vehicles affected

Manufacturer: Motor Coach Industries

ELECTRICAL SYSTEM

Defect Description

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 su... Read more

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.

10,016 vehicles affected

Manufacturer: Motor Coach Industries

INTERIOR LIGHTING

Defect Description

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 AN... Read more

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.

312 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

ELECTRONIC STABILITY CONTROL (ESC)

Defect Description

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 ... Read more

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.

1,962 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

Defect Description

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.

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.

138 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

POWER TRAIN:AXLE ASSEMBLY

Defect Description

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 ADAPT... Read more

Consequence

THIS COULD RESULT IN A LOSS OF THE WHEEL POSSIBLY RESULTING IN A CRASH.

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.

335 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

No complaints found for this vehicle.

Technical Service Bulletins — 2010 MCI D4000

11 manufacturer communications from 9 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
980000 UNKNOWN OR OTHER	2
110000 ELECTRICAL SYSTEM	2
102000 POWER TRAIN:MANUAL TRANSMISSION	1
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	1
103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)	1
021300 SUSPENSION:FRONT:SHOCK ABSORBER	1
350000 EQUIPMENT	1
030000 SERVICE BRAKES, HYDRAULIC	1

220000 SEATS

Technical Service Information Bulletin describing the replacement of seating backrest attachment hardware with the addition of a mechanical lock nut on specifically equipped buses manufactured prior to model year 2020.

030000 SERVICE BRAKES, HYDRAULIC

This Technical Service Information Bulletin (TSIB) describes an update from Meritor for the bolt torque application requirements on hub-to-rotor bolts for the front, drive and tag axles, on specific coaches equipped with Meritor EX225 disc

350000 EQUIPMENT

This Service Bulletin provides a checklist of actions to perform on a daily, weekly and monthly basis for parked coaches before they are considered ready for driving.

110000 ELECTRICAL SYSTEM

This Service Bulletin informs owners of the procedure to clean the batteries and reapply corrosion inhibitor every 6000 miles or 3 months, whichever first occurs.

110000 ELECTRICAL SYSTEM

Motor Coach Industries (MCI) has received field reports of the alternator bracket on 2010 and 2013 Cummins ISX engine exhibi;ting signs of fatigue and cracking. MCI is instructing customers operating a D or J4500 serues ciacg eqkyuooed wut

021300 SUSPENSION:FRONT:SHOCK ABSORBER

MOTOR COACH INDUSTRIES (MCI): RED 185 DUROMETER POLYURETHANE BUSHINGS WERE REPLACED WITH 288 POLYURETHANE BUSHINGS IN SHOCK ABSORBERS THAT IN COLD TEMPERATURES, WILL FAIL, CAUSING ABSORBER STUD TO BREAK, AT BUSHING, AND COACH IS NOT OPERA

980000 UNKNOWN OR OTHER

MOTOR COACH INDUDSTRIES: INFORMATION ON REPLACING THE COOLANT PUMP THAT MAY HAVE A PROBLEM. *RM

102000 POWER TRAIN:MANUAL TRANSMISSION

MOTOR COACH INDUSTRIES SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. THERE MAY BE A HARSH DOWNSHIFT, RPM FLARE, OR THE TRANSMISSION MAY LOCK. *RM

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

MOTOR COACH INDUSTRIES SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. THERE MAY BE A HARSH DOWNSHIFT, RPM FLARE, OR THE TRANSMISSION MAY LOCK. *RM

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

MOTOR COACH INDUSTRIES SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. THERE MAY BE A HARSH DOWNSHIFT, RPM FLARE, OR THE TRANSMISSION MAY LOCK. *RM

980000 UNKNOWN OR OTHER

There are no Manufacturer Communications in accordance with 49 CFR 579.5 to report for April 2024 for Motor Coach Industries.

NHTSA Safety Investigations — MCI D4000

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

RQ — Closed — Model Year: 2011

Exhaust Bellows Pipe Fracture Recall

By letter dated April 15, 2013, Motor Coach Industries (MCI) notified the Office of Defects Investigation (ODI) of a safety defect that may exist in certain model year (MY) 2012 and 2013 MCI D-model coaches built from December 22, 2011 to May 19, 2012 equipped with the Cummins 2010 EPA ISX 12 Liter ... engine.These vehicles may have had an incorrect installation of the exhaust pipe.If installed incorrectly, the elbow pipe may prematurely fail and if a Diesel Particulate Filter regeneration event occurs, the hot exhaust gases could cause a fire, resulting in injury to persons and/or damage to property.MCI conducted an inspect and repair if necessary recall campaign identified by NHTSA Recall No: 13V-142. At the time MCI believed that 13V-142 covered all the vehicles potentially having the safety defect. However, ODI review of EWR data indicated that other vehicles outside the scope of 13V-142 also experienced the same defect condition. Subsequently, in May 2017, MCI expanded the scope of the previous recall to include certain MY 2011-2012 MCI D-model coaches manufactured from January 31, 2011 to May 19, 2012, identified by NHTSA Recall No: 17V-337.In April 2013 when MCI conducted recall 13V-142 to remedy incorrectly installed bellows pipes on certain MCI model year 2012 and 2013 D model vehicles they also changed the bellows pipe assembly process in then current production.With recall 17V-337 MCI expanded the first recall by an additional 178 vehicles they felt also had not had the bellows pipe properly installed.Following the receipt of complaints and EWR data alleging bellows pipe failures on vehicles built after the implementation of the improved assembly process, NHTSA opened this Recall Query to assess the scope and adequacy of these two safety recalls and MCI's recall decision making process.Analysis of the failure data provided by MCI to this investigation found that the improved assembly process reduced the failure rate but did not eliminate the defect all together.In response to this investigation, MCI agreed to conduct recall 18V-309. This latest recall includes and expands upon the vehicle population of the prior recalls, and implements a new remedy that adds a mesh component to the bellows assembly to reduce vibration.This remedy was also implemented in production in 2015.Vehicles built after this date do not have an elevated failure rate even with a significant amount of time in service.With recall action 18V-309 taken by MCI this investigation is closed. Further use of agency resources does not appear to be warranted. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist on other model or MY vehicles outside of the recall scope. The agency reserves the right to take further action if warranted by the circumstances.Read more

PE — Closed — Model Year: 2005

ALTERNATOR CABLE CHAFING

THIS INVESTIGATION WAS PROMPTED BY A REVIEW OF SERVICE BULLETINS PROVIDED BYMCI TO THE AGENCY. MOTOR COACH INDUSTRIES (MCI) SUBMITTED A SERVICE BULLETIN/PRODUCT IMPROVEMENT CAMPAIGN (#3016) IN THEIR 579.5 MONTHLY SUBMISSION REGARDING AN ALTERNATOR CABLE CHAFING ISSUE ON D SERIES COACHES EQUIPPED WIT... Read more

MCI D4000 — All Years Overview

Complete safety history for the MCI D4000 across all model years (1997–2021).

111 Total Recalls

0 Total Complaints

2 Investigations

0 Reported Crashes

0 Reported Fires

0 Reported Deaths

MCI D4000 — Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls
2021	1	View
2020	1	View
2019	1	View
2018	4	View
2017	2	View
2016	3	View
2015	5	View
2014	4	View
2013	2	View
2012	7	View
2011	9	View
2010 (current)	6
2009	6	View
2008	4	View
2007	7	View
2006	9	View
2005	8	View
2004	7	View
2003	7	View
2002	6	View
2001	5	View
2000	4	View
1999	1	View
1998	1	View
1997	1	View

Other MCI Models

Model	Recalls	Complaints
102A3	0	0	View
102B3	0	0	View
102C3	0	0	View
102D	0	0	View
102D3	0	0	View
102D3ISTV	0	0	View
102DL	0	0	View
102DL3	0	0	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2010 MCI D4000

Technical Service Bulletins — 2010 MCI D4000

Most Affected Components

NHTSA Safety Investigations — MCI D4000

MCI D4000 — All Years Overview

MCI D4000 — Year by Year

Other MCI Models