2009 MCI D4500
11 recalls — 0 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.
14V329000 Jun 16, 2014
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
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.
12V250000 May 31, 2012
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.
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.
09V350000 Sep 9, 2009
STEERING:LINKAGES:TIE ROD ASSEMBLY
Defect Description
MCI IS RECALLING MODEL YEAR 2009 D4500/4505 COACHES EQUIPPED WITH THE MERITOR FH 946 14,000 LB RATED STEERABLE TAG AXLE. DUE TO INSUFFICIENT CLAMPING FORCE OF THE CYLINDER LOCK PLATE, IT MAY MOVE FROM ITS NORMAL SET POSITION, WHICH IN TURN COULD RESULT IN THE TAG AXLE NOT AUTOMATICALLY LOCKING, OR ... Read more
Consequence
IF THE TAG AXLE DOES NOT LOCK ABOVE 20 MPH, THERE IS A LOSS OF LATERAL FORCE CONTROL OF THE TAG AXLE THAT CAN AFFECT THE STEERING OF THE VEHICLE. ALSO DURING A TURN THE REAR OF THE VEHICLE WILL SWING FURTHER OUT IN THE OPPOSITE DIRECTION OF THE TURN AND COULD RESULT IN THE COACH STRIKING ANOTHER VE... Read more
Remedy
DEALERS WILL PROVIDE REPLACEMENT CLAMPS THAT DO NOT HAVE PAINT ON THE CLAMPING SURFACES. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2009. OWNERS MAY CONTACT MCI CUSTOMER SERVICE LINE AT 1-800-241-2947.
09V196000 Jun 1, 2009
STEERING
Defect Description
MCI IS RECALLING CERTAIN MODEL YEAR 2008 AND 2009 MOTOR COACHES, MODEL J4500 MANUFACTURED BETWEEN OCTOBER 2007 AND APRIL 2009; 2009 MOTOR COACHES MODELS D4000ISTV, D4005, D4500, AND D4505 MANUFACTURED BETWEEN JANUARY AND JULY 2009; 2010 D4500 COACHES MANUFACTURED BETWEEN DECEMBER 2008 AND APRIL 2009... Read more
Consequence
WITH A BROKEN SAS DRIVING TAB, THE ELECTRONIC STABILITY CONTROL (ESC) WILL NOT FUNCTION PROPERLY, WHICH COULD POSSIBLY RESULT IN A VEHICLE CRASH.
Remedy
MCI WILL NOTIFY OWNERS AND THE VEHICLES WILL BE REPAIRED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JULY 10, 2009. OWNERS MAY CONTACT MCI AT 1-800-241-2947.
No complaints found for this vehicle.
Technical Service Bulletins — 2009 MCI D4500
8 manufacturer communications from 6 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 980000 UNKNOWN OR OTHER | 2 |
| 102000 POWER TRAIN:MANUAL TRANSMISSION | 1 |
| 103000 POWER TRAIN:AUTOMATIC TRANSMISSION | 1 |
| 103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM) | 1 |
| 110000 ELECTRICAL SYSTEM | 1 |
| 350000 EQUIPMENT | 1 |
| 030000 SERVICE BRAKES, HYDRAULIC | 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 3139
Sep 17, 2020
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.
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
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 (current) | 11 | 0 | |
| 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 | 7 | 1 | View |
| 2001 | 5 | 0 | View |
| 2000 | 3 | 0 | View |
| 1999 | 1 | 0 | View |
| 1998 | 1 | 0 | View |
| 1997 | 1 | 0 | View |