2006 MCI D4505

11 recalls — 0 complaints — 12 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

POWER TRAIN:DRIVELINE:DRIVESHAFT

Defect Description

Motor Coach Industries (MCI) is recalling certain model year 1993-1995 102DL3 motor coaches manufactured November 1992 to January 1995, and 2006 and 2008 D4505 motor coaches manufactured June 2005 to April 2008. The affected buses are equipped with a driveshaft with a compressed length of 30 inches... Read more

Consequence

If the driveshaft escapes containment it can strike the trailing axle tie rod and components of the trailing axle locking system potentially causing the trailing axle steering and caster locking mechanisms to unlock. If this occurs, the driver may experience loss of steering control of the vehicle, ... Read more

Remedy

MCI will notify owners, and dealers will add a secondary drive shaft containment hoop forward of the tag axle support structure, free of charge. The recall began on August 7, 2014. Owners may contact MCI customer service at 1-847-285-2090. MCI's number for this recall is 414.

325 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

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

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.

1,007 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

Defect Description

MCI IS RECALLING 103 MY 2005-2008 D4500 AND D4505 COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES AND A ZF TRANSMISSION. CUSTOMERS MAY EXPERIENCE A POSSIBLE INTERFERENCE BETWEEN THE DRIVE SHAFT U-JOINT BEARING CAP BOLTS AND THE TAG AXLE CENTER BEAM ASSEMBLY.

Consequence

INTERFERENCE BETWEEN THE BEARING CAP BOLTS AND THE AXLE CENTER BEAM ASSEMBLY COULD CAUSE THE BEARING CAP BOLTS TO SHEAR, FREEING THE BEARINGS AND POSSIBLY RELEASING THE DRIVE SHAFT, INCREASING THE RISK OF VEHICLE DAMAGE OR A CRASH.

Remedy

DEALERS WILL INSTALL A TAG AXLE SUSPENSION SPACER KIT AND AN SPL250 DRIVESHAFT RETROFIT KIT TO LIMIT THE SUSPENSION TRAVEL AND REDUCE THE SWING DIAMETER OF THE DRIVESHAFT THEREBY INCREASING THE CLEARANCE AND ELIMINATING ANY POSSIBLE INTERFERENCE. THE RECALL BEGAN ON FEBRUARY 25, 2009. OWNERS MAY C... Read more

103 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

EQUIPMENT

Defect Description

MCI IS RECALLING 1,893 MY 2002-2008 D MODEL AND MY 2001-2008 E AND J4500 MOTOR COACHES EQUIPPED WITH ZF TRANSMISSIONS. THERE IS A POTENTIAL FOR THE SHIFT SELECTOR TO MALFUNCTION AS A RESULT OF A CELL PHONE OR RADIO BEING PLACED IN CLOSE PROXIMITY TO THE SHIFTER CONTROL PAD.

Consequence

WHEN THIS HAPPENS, THE SHIFT SELECTOR MAY MOVE INTO REVERSE WITHOUT DRIVER KNOWLEDGE INCREASING THE RISK OF A CRASH.

Remedy

MCI IS WORKING WITH ZF AND HAS CREATED A SOFTWARE UPDATE THAT PROTECTS AGAINST THE POTENTIAL FOR TRANSIENT ANALOG OR DIGITAL SIGNAL INTERFERENCE. THE RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2008. .OWNERS MAY CONTACT MCI AT 1-800-333-0371 AND ZF AT 1-734-416-6200.

1,893 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

VISIBILITY:GLASS, SIDE/REAR

Defect Description

MCI IS RECALLING 185 MY 2006-2007 D4005 AND D4505 MOTOR COACHES EQUIPPED WITH DURA SIDE BODY EGRESS WINDOWS. THESE COACHES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 217, 'BUS EMERGENCY EXITS AND WINDOW RETENTION AND RELEASE.' THE WINDOWS WERE PRODUCED WITH I... Read more

Consequence

THE PURPOSE OF THIS STANDARD IS TO MINIMIZE THE LIKELIHOOD OF OCCUPANTS BEING THROWN FROM THE BUS AND TO PROVIDE A MEANS OF READILY ACCESSIBLE EMERGENCY EGRESS.

Remedy

MCI WILL NOTIFY OWNERS INSTRUCTING THEM TO INSPECT THE WINDOWS FOR SIGNS OF WATER LEAK, WIND NOISE, OR VISIBLE PARTIAL DE-BONDING. WINDOWS SHOWING THESE SIGNS WILL BE REPLACED FREE OF CHARGE BY DURA (PLEASE SEE 07E042). THE RECALL BEGAN ON AUGUST 27, 2007. OWNERS CAN CONTACT DURA AT 1-248-844-161... Read more

185 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

VISIBILITY:GLASS, SIDE/REAR

Defect Description

CERTAIN DURA SIDE BODY EGRESS WINDOWS, SIDE BODY LAVATORY EGRESS WINDOWS, AND NON-EGRESS SIDE BODY WINDOWS MANUFACTURED BETWEEN NOVEMBER 1, 2005, AND JULY 19, 2006, INSTALLED AS ORIGINAL EQUIPMENT ON CERTAIN MY 2006 AND 2007 MOTOR COACH INDUSTRIES (MCI) D COACHES. THE WINDOWS WERE PRODUCED WITH INC... Read more

Consequence

THE PURPOSE OF THIS STANDARD IS TO MINIMIZE THE LIKELIHOOD OF OCCUPANTS BEING THROWN FROM THE BUS AND TO PROVIDE A MEANS OF READILY ACCESSIBLE EMERGENCY EGRESS.

Remedy

MCI WILL NOTIFY OWNERS INSTRUCTING THEM TO INSPECT THE WINDOWS FOR SIGNS OF WATER LEAK, WIND NOISE, OR VISABLE PARTIAL DE-BONDING. WINDOWS SHOWING THESE SIGNS WILL BE REPLACED FREE OF CHARGE BY DURA. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2007. OWNERS CAN CONTACT DURA AT 248-844-1615.

4,284 vehicles affected

Manufacturer: DURA AUTOMOTIVE SYSTEMS, INC.

SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

Defect Description

ON CERTAIN D SERIES MOTOR COACHES, THERE COULD BE A POSSIBLE INTERFERENCE BETWEEN THE DRIVE SHAFT MOUNTING HARDWARE AND THE TAG AXLE STRUCTURE.

Consequence

THE BEARING CAP BOLTS COULD SHEAR, FREEING THE BEARINGS, AND POSSIBLY RELEASING THE DRIVE SHAFT, INCREASING THE RISK OF A CRASH.

Remedy

SHIMS WILL BE INSTALLED ABOVE THE TAG AXLE AIR SPRING MOUNTING BRACKETS TO LIMIT THE SUSPENSION TRAVEL. THE RECALL IS EXPECTED TO BEGIN DURING JANUARY 2007. OWNERS MAY CONTACT MCI AT 1-800-241-2947.

75 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

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

No complaints found for this vehicle.

Technical Service Bulletins — 2006 MCI D4505

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

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

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.

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

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

102000 POWER TRAIN:MANUAL TRANSMISSION

105300 POWER TRAIN:DRIVELINE:DRIVESHAFT

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

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

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 D4505

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

PE — Closed — Model Year: 2011

Tailpipe seperation resulting in fire

During the review of Motor Coach Industries (MCI) Early Warning Reporting (EWR) 2016 Q4 data, field reports were identified that described fires on 2 buses from different regions of the country.These fires were alleged to have occurred as a result of a loose clamp allowing the tailpipe to separate f... rom the exhaust after treatment assembly.During exhaust after treatment regeneration high temperature gases were directed at the plastic rear bumper.Prior to the fires, there were no indications (such as soot trails) that the clamps were loose.When contacted, the fleet maintenance manager stated all maintenance schedules and DOT inspections had been performed without a failure citation of the exhaust systems. MCI addressed the issue by installing additional brackets to the pipe on all the other buses in the fleet ensuring the tailpipe stayed intact should the clamp lose torque.In correspondence with another fleet using the same style bus, the fleet safety manager described having loose clamps resulting in fires.The MCI fix for the second fleet was to install a shield at the rear bumper to deflect the high temperature exhaust gases in the event of the tailpipe separated from the exhaust after treatment system.This fix was different from the first fleet.During review of communications submitted in March 2017, the Office of Defects Investigation (ODI) identified MCI Service Bulletin No. 309 regarding a maintenance procedure of the exhaust system Torca Accuseal clamp.This bulletin instructed that a new clamp must be utilized after any service or maintenance is performed in which the existing clamp was loosened or removed.ODI requested further information on this bulletin and received warranty claims showing loose tailpipes.MCI has taken the position that fires at the clamp location were due to improper maintenance by the fleets.After analysis of data, provided by MCI to ODI in response to an information request letter, ODI found there was not an increasing number (claim rate of 1.1%) of failures and fires even with portions of the fleet having over seven years in service.The 4 fires identified were from 2 fleets.ODI contacted the fleets with fire incidents and was informed that one of the two buses involved in the fire incidents was sold in 2016 and other fleet does not have maintenance records since they only keep records for one year.ODI is closing the investigation as no actionable trend has been identified.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. The agency reserves the right to take further action if warranted by the circumstances.Read more

MCI D4505 — All Years Overview

Complete safety history for the MCI D4505 across all model years (2000–2022).

135 Total Recalls

1 Total Complaints

1 Investigations

0 Reported Crashes

0 Reported Fires

0 Reported Deaths

MCI D4505 — Year by Year

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

Year	Recalls	Complaints
2022	1	0	View
2021	2	0	View
2020	7	0	View
2019	8	0	View
2018	7	0	View
2017	5	1	View
2016	4	0	View
2015	8	0	View
2014	7	0	View
2013	6	0	View
2012	8	0	View
2011	8	0	View
2010	10	0	View
2009	9	0	View
2008	9	0	View
2007	11	0	View
2006 (current)	11	0
2005	6	0	View
2004	2	0	View
2003	2	0	View
2002	2	0	View
2001	1	0	View
2000	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