2008 MCI D4500
8 recalls — 0 complaints — 12 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.
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.
11V524000 Oct 26, 2011
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.
10V114000 Mar 24, 2010
EQUIPMENT ADAPTIVE/MOBILITY
Defect Description
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 ... Read more
Consequence
THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE WITHOUT THE RESTRAINT BELT PROPERLY BUCKLED.
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 EXPECTED TO BEGIN DURING APRIL 2010. OWNERS MAY CONTACT RICON CUSTOMER SERVIC... Read more
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.
09V446000 Nov 18, 2009
ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR
Defect Description
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 O... Read more
Consequence
THIS COULD RESULT IN A FIRE.
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.
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.
08V063000 Feb 7, 2008
STEERING:GEAR BOX:SHAFT PITMAN
Defect Description
MOTOR COACH INDUSTRIES (MCI) IS RECALLING 24 MY 2008 D4505, D4500, D4000ISTV MOTOR COACHES EQUIPPED WITH TRW STEERING GEARS, MODELS TAS85. THESE STEERING GEARS CONTAIN POTENTIALLY DEFECTIVE SECTOR SHAFTS WITH AN INCORRECT GEAR TOOTH WHICH MAY INTERFERE WITH THE RACK-PISTON TEETH, RESULTING IN A S... Read more
Consequence
THIS CONDITION HAS THE POTENTIAL TO CAUSE THE STEERING GEAR TO STALL AND RESTRICT THE STEERING TURNING ANGLE OF THE VEHICLE WHICH COULD RESULT IN A VEHICLE CRASH.
Remedy
MCI IS WORKING WITH TRW TO REPLACE THE DEFECTIVE STEERING GEAR (PLEASE SEE 07E101). THE RECALL BEGAN ON FEBRUARY 11, 2008. OWNERS MAY CONTACT TRW AT 1-765-429-1768 OR MCI AT 1-204-287-4982.
No complaints found for this vehicle.
Technical Service Bulletins — 2008 MCI D4500
12 manufacturer communications from 7 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 102000 POWER TRAIN:MANUAL TRANSMISSION | 2 |
| 105300 POWER TRAIN:DRIVELINE:DRIVESHAFT | 2 |
| 980000 UNKNOWN OR OTHER | 2 |
| 061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL | 1 |
| 105100 POWER TRAIN:DRIVELINE:UNIVERSAL JOINT | 1 |
| 103000 POWER TRAIN:AUTOMATIC TRANSMISSION | 1 |
| 103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM) | 1 |
| 110000 ELECTRICAL SYSTEM | 1 |
TSIB 21-01
Dec 14, 2021
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
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-320
Feb 24, 2009
061200 ENGINE AND ENGINE COOLING:ENGINE:DIESEL
ZF FRIEDRICHSHAFEN: TAG AXLE/DRIVE SHAFT INTERFERENCE-DETROIT DIESEL SERIES 60 ENGINE AND ZF TRANSMISSION. EXPERIENCE INTERFERENCE BETWEEN DRIVE SHAFT U JOINT BEARING CAP BOLTS AND TAG AXLE CENTER BEAM. MODEL YEARS UNKNOWN. *PE
SB-320
Feb 24, 2009
102000 POWER TRAIN:MANUAL TRANSMISSION
ZF FRIEDRICHSHAFEN: TAG AXLE/DRIVE SHAFT INTERFERENCE-DETROIT DIESEL SERIES 60 ENGINE AND ZF TRANSMISSION. EXPERIENCE INTERFERENCE BETWEEN DRIVE SHAFT U JOINT BEARING CAP BOLTS AND TAG AXLE CENTER BEAM. MODEL YEARS UNKNOWN. *PE
SB-320
Feb 24, 2009
105300 POWER TRAIN:DRIVELINE:DRIVESHAFT
ZF FRIEDRICHSHAFEN: TAG AXLE/DRIVE SHAFT INTERFERENCE-DETROIT DIESEL SERIES 60 ENGINE AND ZF TRANSMISSION. EXPERIENCE INTERFERENCE BETWEEN DRIVE SHAFT U JOINT BEARING CAP BOLTS AND TAG AXLE CENTER BEAM. MODEL YEARS UNKNOWN. *PE
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 (current) | 8 | 0 | |
| 2007 | 7 | 0 | View |
| 2006 | 9 | 0 | View |
| 2005 | 10 | 0 | View |
| 2004 | 7 | 1 | View |
| 2003 | 7 | 0 | View |
| 2002 | 7 | 1 | View |
| 2001 | 5 | 0 | View |
| 2000 | 3 | 0 | View |
| 1999 | 1 | 0 | View |
| 1998 | 1 | 0 | View |
| 1997 | 1 | 0 | View |