2012 MCI D4505

8 recalls — 0 complaints — 16 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

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

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

Defect Description

Motor Coach Industries (MCI) is recalling certain 2011-2012 MCI D4000, D4005, D4500 and D4505 coaches equipped with Cummins ISX 12 liter engines. The vehicles may have an incorrectly installed exhaust bellow pipe, resulting in a bend in the pipe which can cause its premature failure.

Consequence

If the pipe fails and a diesel regeneration cycle occurs, the hot exhaust gases will increase the risk of a fire.

Remedy

MCI will notify owners and dealers will inspect and replace any deformed or failed bellow pipes if necessary, free of charge. The recall began on June 15, 2017. Owners may contact Motor Industries at 1-800-241-2947. MCI's number for this recall is SB 397B.

143 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

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

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

Defect Description

Motor Coach Industries (MCI) is recalling certain model year 2012-2013 D4000, D4000ISTV, D4005, D4500, and D4505 motorcoaches manufactured from May 2012 through December 2012 and equipped with a Cummins ISX EPA 2010 engine. In the affected buses, the bellows pipe in the exhaust system may have been... Read more

Consequence

During a regeneration process to clean exhaust emissions, if the bellows pipe has failed, the hot exhaust gases may not be contained, resulting in a fire.

Remedy

MCI will notify owners and dealers will inspect and replace the bellows pipes, as necessary, free of charge. The recall began on April 29, 2013. Customers may contact MCI at 1-847-285-2000.

155 vehicles affected

Manufacturer: Motor Coach Industries

ELECTRICAL SYSTEM

Defect Description

MOTOR COACH INDUSTRIES, INC (MCI) IS RECALLING CERTAIN MODEL YEAR 2012 D4505, D4500, AND D4000ISTV MOTOR COACHES, EQUIPPED WITH A SEDAN STYLE ENTRANCE DOOR AND AN ACTIA MULTIPLEX SYSTEM. THIRTY MINUTES AFTER THE PARK BRAKE IS SET AND THE IGNITION IS TURNED OFF, THE ENTRANCE DOOR WILL CLOSE WITHOUT W... Read more

Consequence

THE ENTRANCE DOOR WILL CLOSE WITHOUT WARNING, INCREASING THE RISK OF PERSONAL INJURY TO PEOPLE ENTERING OR EXITING THE BUS.

Remedy

MCI WILL NOTIFY OWNERS, AND REMEDY THE AFFECTED COACHES BY REPROGRAMMING THE MULTIPLEX SYSTEM, FREE OF CHARGE. THE RECALL BEGAN ON APRIL 11, 2012. OWNERS MAY CONTACT MCI AT 1-800-241-2947.

46 vehicles affected

Manufacturer: MOTOR COACH INDUSTRIES, INC

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

No complaints found for this vehicle.

Technical Service Bulletins — 2012 MCI D4505

16 manufacturer communications from 16 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
103000 POWER TRAIN:AUTOMATIC TRANSMISSION	2
060000 ENGINE (PWS)	2
110000 ELECTRICAL SYSTEM	2
103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER	1
063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM	1
061320 ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER	1
070000 FUEL SYSTEM, GASOLINE	1
356000 EQUIPMENT ADAPTIVE/MOBILITY	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.

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.

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.

356000 EQUIPMENT ADAPTIVE/MOBILITY

This Service Bulletin supersedes Service Bulletin 424 in its entirety and informs customers that MCI was notified by Cummins Inc. that it has issued a campaign to addresses the ISX lubricating oil filter bypass valve in addition to the prev

070000 FUEL SYSTEM, GASOLINE

This Service Bulletin informs customers that MCI was notified by Cummins Inc. that it has released Campaign C1638 that addresses the ISX lubricating oil filter bypass valve in addition to the previous fuel pump repair actions outlined in MC

061320 ENGINE AND ENGINE COOLING:ENGINE:OTHER FUEL TYPES:TURBO/SUPERCHARGER

This Service Bulletin informs affected customers that MCI was notified by Cummins Inc. that it has issued a campaign to address ISX high pressure fuel pump ceramic plunger fractures as well as the potential of damage to the roller/tappet as

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

This Service Bulletin informs affected customers that the diesel exhaust fluid (DEF) pressure line may exhibit signs of fatigue and melting on model year 2011-2013 MCI D model coaches, and that MCI will remedy the affected coaches at no cos

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

This Service Bulletin supersedes Service Bulletin 392 in its entirety and informs affected customers that coaches equipped with a Cummins 2010 engine can experience intermittent faults of the engine and/or transmission of the mulitplex cont

110000 ELECTRICAL SYSTEM

This Service Bulletin informs affected customers that due to the Actia's module internal circuit characteristic the potential may exist in which both the high side and low side output of power management module (PMM)1 may be active at the s

060000 ENGINE (PWS)

This Service Bulletin informs customers that MCI was notified by Cummins Inc. that it has released Campaign C1344 that addresses a calibration change, which Cummins advises will improve the engine and aftertreatment reliability on Cummins I

103000 POWER TRAIN:AUTOMATIC TRANSMISSION

This Service Bulletin informs affected customers that coaches equipped with a Cummins 2010 engine may experience intermittent faults on the engine and/or transmission without having the designated warning tell-tale (check engine light and/o

060000 ENGINE (PWS)

This Service Bulletin informs affected customers that MCI was notified by Cummins Inc. that it has issued campaign C1241 that addresses a calibration issue, which results in the engine brakes being energized with 24 volts rather than the re

103700 POWER TRAIN:AUTOMATIC TRANSMISSION:TORQUE CONVERTER

This Service Bulletin informs affected customers that the retention nut utilized on the Leece Neville alternator pulley installation is not maintaining the proper torque which may result in alternator bearing failure on model year 2011-2012

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 (current)	8	0
2011	8	0	View
2010	10	0	View
2009	9	0	View
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