2016 MCI D4500

5 recalls — 0 complaints — 22 TSBs

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

EQUIPMENT ADAPTIVE/MOBILITY:WHEELCHAIR LIFT/RAMP

Defect Description

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 ... Read more

Consequence

Beacons that do not provide proper illumination may be less visible to wheelchair lift users, increasing the risk of injury.

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.

2,114 vehicles affected

Manufacturer: Motor Coach Industries

SEAT BELTS

Defect Description

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... Read more

Consequence

Inability to use the seat belt may increase the risk of injury in the event of a crash.

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 may contact MCI customer service at 1-800-241-2947. MCI's number for this rec... Read more

641 vehicles affected

Manufacturer: Motor Coach Industries

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

Defect Description

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.

Consequence

If the pipe develops a hole, during a regeneration cycle, hot exhaust gases may leak out, increasing the risk of a fire.

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.

1,123 vehicles affected

Manufacturer: Motor Coach Industries

SEATS

Defect Description

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... Read more

Consequence

If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.

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. Owners may contact MCI at 1-800-241-2947. MCI's number for this recall is SB 431... Read more

607 vehicles affected

Manufacturer: Motor Coach Industries

No complaints found for this vehicle.

Technical Service Bulletins — 2016 MCI D4500

22 manufacturer communications from 19 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
350000 EQUIPMENT	5
110000 ELECTRICAL SYSTEM	4
060000 ENGINE (PWS)	3
356000 EQUIPMENT ADAPTIVE/MOBILITY	2
162300 STRUCTURE:BODY:DOOR	1
070000 FUEL SYSTEM, GASOLINE	1
060000 ENGINE AND ENGINE COOLING	1
160000 STRUCTURE	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.

110000 ELECTRICAL SYSTEM

This Technical Instruction describes how to upgrade the Delco alternator indicator lamp ring terminal.

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.

080000 FUEL SYSTEM, DIESEL

This Procedure outlines the steps to add an insulator to the fuel tank strap assembly to reduce excessive movement of the fuel tank. This procedure applies to 2015 - 2020 D4500 coaches equipped with an aluminum fuel tank.

356000 EQUIPMENT ADAPTIVE/MOBILITY

350000 EQUIPMENT

This Procedure outlines steps to replace the radio tray slides and reinforce the tray to avoid the tray from rattling and cracking.

160000 STRUCTURE

This Procedure outlines the steps to replace the aluminum rivets with stainless steel nuts and bolts to secure the rad panel due to galvanic corrosion.

350000 EQUIPMENT

This Procedure outlines the steps to replace the aluminum rivets with stainless steel nuts and bolts to secure the rad panel due to galvanic corrosion.

356000 EQUIPMENT ADAPTIVE/MOBILITY

This Procedure outlines the steps to replace the aluminum rivets with stainless steel nuts and bolts to secure the rad panel due to galvanic corrosion.

060000 ENGINE AND ENGINE COOLING

This Procedure outlines the steps to install a relief valve on the air compressor for coaches equipped with DD13 engines.

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

This Service Bulletin informs owners of D series coaches equipped with a Delco 55 SI alternator MCI P/N (07-03-1310) to clean the alternators every 6,000 miles using the procedure as recommended by Delco.

110000 ELECTRICAL SYSTEM

Field Service Campaign D18M2 GHG17 Detroit? DD13? Software Reprogramming and Emission

350000 EQUIPMENT

This Service Bulletin informs affected customers that the GFCI outlet(s) on the Sensata inverter may require replacement on model year 2014-2017 MCI D Series and model year 2014-2017 MCI J4500 model coaches, and that replacement parts are a

060000 ENGINE (PWS)

This Service Bulletin informs affected customers that the potential may exist for heat damage to occur to the rear bumper asembly on coaches equipped with an ISX G engine on model year 2015-2018 MCI D Series model coaches, and that MCI has

060000 ENGINE (PWS)

This revised Service Bulletin was issued to reflect specific unit numbers in place of a VIN range list, and informs affected customers that Cummins has released Campaign C1846 that addresses calibration issues on ISX12 2013 engines in cert

350000 EQUIPMENT

This Service Bulletin informs affected customers that MCI has become aware that rattling of the parcel rack compartment doors may occur on model year 2014-2017 MCI D Series and 2014-2017 MCI J4500 model coaches, and that MCI will remedy the

070000 FUEL SYSTEM, GASOLINE

THIS SERVICE BULLETIN INFORMS AFFECTED CUSTOMERS THAT MCI WAS NOTIFIED BY AMEREX CORPORATION THAT THE GAS DETECTION PORTION OF THE AMEREX SAFETYNET SYSTEM IN CERTAIN CASES MAY BE DISABLED, AND THE OPERATOR DISPLAY MAY NOT INDICATE THAT THE

060000 ENGINE (PWS)

THIS SERVICE BULLETIN INFORMS AFFECTED CUSTOMERS THAT MCI WAS NOTIFIED BY CUMMINS INC. THAT CUMMINS HAS RELEASED CAMPAIGN C1846 THAT ADDRESSES CALIBRATION ISSUES ON ISX12 2013 ENGINES IN CERTAIN MOTOR COACH OPERATIONS ON MODEL YEAR 2014-201

162300 STRUCTURE:BODY:DOOR

THIS SERVICE BULLETIN INFORMS AFFECTED CUSTOMERS THAT MCI HAS MADE AN IMPROVEMENT TO THE PARCEL RACK COMPARTMENT DOOR INSTALLATION WHICH WILL MINIMIZE THE PARCEL RACK COMPARTMENT DOOR RATTLING ON MODEL YEAR 2014-2017 MCI D MODEL COACHES AND

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 (current)	5	0
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	7	1	View
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