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2002 MCI D4500

7 recalls — 1 complaints — 8 TSBs

25V853000 Dec 10, 2025
STRUCTURE:BODY:DOOR
Defect Description
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. A... Read more
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.
15,454 vehicles affected
Manufacturer: Motor Coach Industries, Inc
13V498000 Oct 17, 2013
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
10V087000 Mar 9, 2010
EQUIPMENT ADAPTIVE/MOBILITY
Defect Description
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 R... Read more
Consequence
IF THE COACH IS IN MOTION, POTENTIAL INJURY TO PERSONS AND/OR DAMAGE TO OTHER VEHICLES OR PROPERTY COULD OCCUR.
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 CUSTOMER SERVICE LINE AT 1-800-241-2947.
4,457 vehicles affected
Manufacturer: MOTOR COACH INDUSTRIES, INC
09V432000 Nov 3, 2009
INTERIOR LIGHTING
Defect Description
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.
Consequence
A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.
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 MCI CUSTOMER SERVICE AT 1-800-241-2947.
701 vehicles affected
Manufacturer: MOTOR COACH INDUSTRIES, INC
06V481000 Dec 19, 2006
ELECTRICAL SYSTEM:12V/24V/48V BATTERY
Defect Description
ON CERTAIN MOTOR COACHES, THE BOOST CONNECTOR HOUSING CAN FAIL OVER TIME, EXPOSING THE POSITIVE AND NEGATIVE TERMINALS.
Consequence
THIS COULD RESULT IN THE GROUNDING OF AN UNPROTECTED CIRCUIT AND COULD LEAD TO A THERMAL EVENT IF NOT CORRECTED.
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 AT 1-800-241-2947.
1,617 vehicles affected
Manufacturer: MOTOR COACH INDUSTRIES, INC
06V140000 Apr 27, 2006
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
Defect Description
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.
4,765 vehicles affected
Manufacturer: MOTOR COACH INDUSTRIES, INC
02V103000 Apr 4, 2002
ELECTRICAL SYSTEM:WIRING
Defect Description
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.
Consequence
AS A CONSEQUENCE OF THIS LOCK UP, THE FUNCTIONS AND SYSTEMS THAT ARE PART OF THE MULTIPLEX SYSTEM WILL REMAIN AT THEIR STATUS IMMEDIATELY PRIOR TO THE LOCKUP. THIS COULD AFFECT THE ELECTRICAL OPERATION OF BRAKE LIGHTS, TURN SIGNALS, IGNITION, INSTRUMENTATION, ETC.
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 BEGIN DURING APRIL 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALE... Read more
300 vehicles affected
Manufacturer: MOTOR COACH IND., INC.

Complaint Statistics

1 total complaints

Top Reported Components

ComponentComplaints
SERVICE BRAKES, AIR1
SERVICE BRAKES, AIR Apr 19, 2005
Incident date: Jan 1, 1901
DEFECTIVE AIR BRAKE EQUIPMENT ON MCI D4500 BUSES.*MR IF THERE IS LESS THAN 90 PCI IN THE AIR SYSTEM THERE IS AN AUDIBLE BUZZER AND THE HAZARD LIGHT ILLUMINATES INDICATING LOW AIR. THE EMERGENCY BRAKE SYSTEM DOES NOT WORK UNTIL THE AIR PRESSURE IS ALMOST "0" ON THE MANOMETER ON THE DASHBOARD. *BF... Read more

Technical Service Bulletins — 2002 MCI D4500

8 manufacturer communications from 5 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

ComponentBulletins
980000 UNKNOWN OR OTHER2
105100 POWER TRAIN:DRIVELINE:UNIVERSAL JOINT1
105300 POWER TRAIN:DRIVELINE:DRIVESHAFT1
102000 POWER TRAIN:MANUAL TRANSMISSION1
103000 POWER TRAIN:AUTOMATIC TRANSMISSION1
103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)1
110000 ELECTRICAL SYSTEM1
SB 3120 Oct 7, 2019
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.
SB-357 Apr 25, 2011
980000 UNKNOWN OR OTHER
MOTOR COACH INDUDSTRIES: INFORMATION ON REPLACING THE COOLANT PUMP THAT MAY HAVE A PROBLEM. *RM
354 Feb 24, 2011
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
354 Feb 24, 2011
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
354 Feb 24, 2011
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
SB-277C Feb 24, 2009
105100 POWER TRAIN:DRIVELINE:UNIVERSAL JOINT
MOTOR COACH: TAG AXLE/DRIVESHAFT INTERFERENCE-FIXED TAG AXLE. INTERFERENCE DUE TO LIMITED CLEARANCE BETWEEN DRIVE SHAFT U JOINT BEARING CAP BOLTS AND TAG AXLE CENTER BEAM. MODEL YEARS UNKNOWN. *PE
SB-277C Feb 24, 2009
105300 POWER TRAIN:DRIVELINE:DRIVESHAFT
MOTOR COACH: TAG AXLE/DRIVESHAFT INTERFERENCE-FIXED TAG AXLE. INTERFERENCE DUE TO LIMITED CLEARANCE BETWEEN DRIVE SHAFT U JOINT BEARING CAP BOLTS AND TAG AXLE CENTER BEAM. MODEL YEARS UNKNOWN. *PE
No comms 2024-04 Apr 5, 2024
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.

MCI D4500 — All Years Overview

Complete safety history for the MCI D4500 across all model years (1997–2023).

163 Total Recalls
2 Total Complaints
0 Investigations
1 Reported Crashes
0 Reported Fires
0 Reported Deaths

MCI D4500 — Year by Year

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

Year Recalls Complaints
2023 1 0 View
2022 2 0 View
2021 2 0 View
2020 8 0 View
2019 8 0 View
2018 7 0 View
2017 5 0 View
2016 5 0 View
2015 9 0 View
2014 8 0 View
2013 5 0 View
2012 7 0 View
2011 9 0 View
2010 10 0 View
2009 11 0 View
2008 8 0 View
2007 7 0 View
2006 9 0 View
2005 10 0 View
2004 7 1 View
2003 7 0 View
2002 (current) 7 1
2001 5 0 View
2000 3 0 View
1999 1 0 View
1998 1 0 View
1997 1 0 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