2009 MCI D4505

9 recalls — 0 complaints — 8 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

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

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.

1,962 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

SEATS

Defect Description

MCI IS RECALLING CERTAIN MODEL YEAR 2009-2010 D4005 AND D4505 MOTOR COACHES EQUIPPED WITH A NATIONAL SEATING COMPANY DRIVER'S SEAT CONTAINING A STABILUS BLOC-O-LIFT SHOCK. THE DRIVER'S SEAT SHOCK DAMPER MAY BREAK ALLOWING THE DRIVER'S SEAT TO UNEXPECTEDLY DROP TO THE FLOOR WITHOUT WARNING.

Consequence

IN THE EVENT THIS SHOULD OCCUR WHILE THE BUS IS IN OPERATION, THE DRIVER MAY LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH.

Remedy

MCI WILL NOTIFY OWNERS AND REPLACE THE SEAT SHOCK AS NECESSARY FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 15, 2010. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.

105 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

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

249 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

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.

53 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

SUSPENSION:REAR:SHOCK ABSORBER

Defect Description

MCI IS RECALLING 29 MODEL YEAR 2009 D4505 MOTOR COACHES MANUFACTURED BETWEEN FEBRUARY AND APRIL 2009, EQUIPPED WITH KONI SHOCK ABSORBERS. WHEN THE COACH IS MOVING IN REAR-RISE MODE, THE TAG SUSPENSION AIR SPRINGS CAN GENERATE FORCE THAT EXCEEDS THE MAXIMUM ALLOWABLE TENSILE STRENGTH OF THE SHOCK AB... Read more

Consequence

THIS FAILURE COULD RESULT IN SEPARATION OF THE SHOCK ABSORBER FROM ITS MOUNTING, CAUSING INTERFERENCE BETWEEN THE UPPER PORTION OF THE SUSPENSION AND THE DRIVESHAFT, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

MCI WILL NOTIFY OWNERS AND WILL REPAIR THE COACHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JULY 10, 2009. OWNERS MAY CONTACT MCI AT 1-847-285-2000.

29 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

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.

502 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

No complaints found for this vehicle.

Technical Service Bulletins — 2009 MCI D4505

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

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.

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

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 (current)	9	0
2008	9	0	View
2007	11	0	View
2006	11	0	View
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