2002 MCI J4500
7 recalls — 0 complaints — 39 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.
19V027000 Jan 7, 2019
STEERING:HYDRAULIC POWER ASSIST SYSTEM
Defect Description
Motor Coach Industries (MCI) is recalling certain 2001-2015 J4500 and 1997-2013 102EL3/E4500 coaches equipped with a hydraulic rear axle (tag axle) steering system. The axle's alignment and low hydraulic pressure in the steering system may cause the steering system to lock, causing a loss of steeri... Read more
Consequence
Loss of steering control may increase the risk of a crash.
Remedy
MCI will inspect and repair axle alignment, as necessary, free of charge. MCI issued owners an interim notification on March 26, 2019. Owner notification letters were mailed on May 14, 2021. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is SB 469.
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.
10V373000 Aug 11, 2010
VISIBILITY:GLASS, SIDE/REAR
Defect Description
MCI IS RECALLING CERTAIN MODEL YEAR 2001-2004 E4500, MODEL YEAR 2002-2006 E4500C, MODEL YEAR 2001-2005 J4500, AND MODEL YEAR 2006 J4500C MOTOR COACHES EQUIPPED WITH SE-GI PASSENGER WINDOWS. THE ADHESIVE BOND BETWEEN THE WINDOW GLASS AND THE ALUMINUM WINDOW FRAME ON THE AFFECTED COACHES MAY DEGRADE.
Consequence
IF THE WINDOW GLASS BECOMES PARTIALLY OR COMPLETELY DEBONDED FROM ITS FRAME, THE WINDOW GLASS MAY DETACH AND FALL FROM THE COACH AND CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.
Remedy
DEALERS WILL INSPECT, TEST, AND REPAIR, AS NECESSARY, THE SE-GI WINDOW ASSEMBLIES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 23, 2010. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.
08V603000 Nov 21, 2008
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.
06V241000 Jul 6, 2006
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM
Defect Description
ON CERTAIN MOTOR COACHES EQUIPPED WITH A SLIDE SWITCH TO CONTROL THE DEFROSTER BLOWER SPEED, THERE IS A SPEED CONTROLLER FOR EACH OF THE TWO DEFROSTER FAN MOTORS. THE SPEED CONTROLLER MAY FAIL CAUSING THE FAN MOTOR TO OPERATE CONTINUOUSLY IN THE "HIGH" SPEED MODE, AND THE CARRIER SLIDE SWITCH MAY F... Read more
Consequence
THE SPEED CONTROLLER MAY OVERHEAT AND RESULT IN A THERMAL EVEN, SUCH AS SMOKING OR POSSIBLE FIRE.
Remedy
DEALERS WILL REPLACE THE DEFROSTER SPEED CONTROLLER FREE OF CHARGE. THE RECALL BEGAN ON JULY 20, 2006. OWNERS MAY CONTACT MOTOR COACH AT 1-800-241-2947.
06V140000 Apr 27, 2006
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.
No complaints found for this vehicle.
Technical Service Bulletins — 2002 MCI J4500
39 manufacturer communications from 23 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.
Most Affected Components
| Component | Bulletins |
|---|---|
| 980000 UNKNOWN OR OTHER | 3 |
| 356000 EQUIPMENT ADAPTIVE/MOBILITY | 3 |
| 103000 POWER TRAIN:AUTOMATIC TRANSMISSION | 2 |
| 350000 EQUIPMENT | 2 |
| 160000 STRUCTURE | 2 |
| 042700 SERVICE BRAKES, AIR:SUPPLY:QUICK RELEASE VALVE | 2 |
| 042300 SERVICE BRAKES, AIR:SUPPLY:CHECK VALVE | 2 |
| 102000 POWER TRAIN:MANUAL TRANSMISSION | 2 |
TSIB 22-12
Sep 7, 2022
110000 ELECTRICAL SYSTEM
MCI has released Technical Service Information Bulletin (TSIB) 22-12 to address concerns with water ingress in remote switch box. The TSIB provides guidance on how to rework the box to inhibit water intrusion and connector corrosion
TSIB 21-04
May 3, 2021
160000 STRUCTURE
Technical Service Information Bulletin issued as a reminder to customers of specifically equipped older motor coaches, who performed Service Bulletin 348 in conjunction with NHTSA Recall 10V-373, to continue to inspect the SE-GI side window
D20M4
Mar 18, 2020
350000 EQUIPMENT
DDC Field service campaign for GHG17 Detroit DD13 engines requiring software reprogramming and new emission label replacement. This field service applies only to MCI (Motor Coach Industries) vehicles.
D20M4
Mar 18, 2020
060000 ENGINE AND ENGINE COOLING
DDC Field service campaign for GHG17 Detroit DD13 engines requiring software reprogramming and new emission label replacement. This field service applies only to MCI (Motor Coach Industries) vehicles.
SB 3118
Dec 20, 2018
010000 STEERING
This Service Bulletin informs affected owners of 1997-2013 E4500 and 2001-2015 J4500 model coaches equipped with Rear Axle Steering (RAS) system of the importance of maintaining tag axle caster, and provides the procedure to adjust the cast
SB 3101
Mar 2, 2017
200000 WHEELS
This Service Bulletin informs affected customers that ZF Friedrichshafen AG has released a Service Information bulletin regarding checking axle hubs and wheel heads if an ABS tell-tale lamp is activated during coach operation on MCI J model
SB 3101
Mar 2, 2017
107000 POWER TRAIN:AXLE HUBS
This Service Bulletin informs affected customers that ZF Friedrichshafen AG has released a Service Information bulletin regarding checking axle hubs and wheel heads if an ABS tell-tale lamp is activated during coach operation on MCI J model
SB 3099
Mar 1, 2017
063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
This Service Bulletin informs affected customers of the maintenance procedures for the Torca Accuseal clamp utilized on the connection between the after-treatment system (selective catalyst reduction device) and tailpipe; that the clamp is
SB 3099
Mar 1, 2017
063140 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR
This Service Bulletin informs affected customers of the maintenance procedures for the Torca Accuseal clamp utilized on the connection between the after-treatment system (selective catalyst reduction device) and tailpipe; that the clamp is
SB 3077
Dec 21, 2012
356000 EQUIPMENT ADAPTIVE/MOBILITY
This Service Bulletin informs affected customers that MCI was notified by Shaw Development that the diesel exhaust fluid (DEF) tank cap requires routine cleaning to prevent the potential for crystallization build up at the vent, which may r
SB 3077
Dec 21, 2012
063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
This Service Bulletin informs affected customers that MCI was notified by Shaw Development that the diesel exhaust fluid (DEF) tank cap requires routine cleaning to prevent the potential for crystallization build up at the vent, which may r
SB-390
Sep 21, 2012
161000 STRUCTURE:FRAME AND MEMBERS
MOTOR COACH INC: DRIVE AXLE SUSPENSION SUPPORT STRUCTURE MAY ACCUMULATE WATER CAUSING SUPPORT STRUCTURE DAMAGE DUE TO EXPANSION, IN FREEZING TEMPERATURES, WHILE COACH IS BEING OPERATED. MODELS E4500, J4500. NO MODEL YEARS LISTED.
SB-390
Sep 21, 2012
160000 STRUCTURE
MOTOR COACH INC: DRIVE AXLE SUSPENSION SUPPORT STRUCTURE MAY ACCUMULATE WATER CAUSING SUPPORT STRUCTURE DAMAGE DUE TO EXPANSION, IN FREEZING TEMPERATURES, WHILE COACH IS BEING OPERATED. MODELS E4500, J4500. NO MODEL YEARS LISTED.
SB-367
Dec 14, 2011
103000 POWER TRAIN:AUTOMATIC TRANSMISSION
MOTOR COACH INDUSTRIES: ON SOME COACHES, WATER MAY MIGRATE ONTO/INTO THE TRANSMISSION AND/OR THE FILL TUBE, THROUGH THE BREATHER VENT THAT IS LOCATED ON TOP OF TRANSMISSION. NO MODEL YEARS LISTED. *PE
SB-3066
Oct 5, 2011
120000 EXTERIOR LIGHTING
MOTOR COACH INC: BULLETIN PERTAINING TO THE REVISED REPLACEMENT DIRECTIONAL/SIDE MARKER LIGHTS. TO ELIMINATE POTENTIAL CRACKS THAT RESULT IN WATER INTRUSION, REVISED LIGHTS FOAM BACKING WAS REMOVED BETWEEN MARKER LIGHT AND COACH BODY.
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
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
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
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
SB-3043
Sep 28, 2010
034300 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DIFFERENTIAL PROPORTIONAL VALVE
MCI: TAG UNLOAD VALVE ASSEMBLY. EFFECTIVE WITH UNIT NUMBER 65614, MCI HAS MADE DESIGN CHANGES TO THE TAG UNLOAD VALVE ASSEMBLY INSTALLATION ON SOME MODEL COACHES. THE LONGER LIFE VALVES WILL IMPROVE THE DURABILITY OF THE TAG UNLOAD VALVE
SB-3043
Sep 28, 2010
042700 SERVICE BRAKES, AIR:SUPPLY:QUICK RELEASE VALVE
MCI: TAG UNLOAD VALVE ASSEMBLY. EFFECTIVE WITH UNIT NUMBER 65614, MCI HAS MADE DESIGN CHANGES TO THE TAG UNLOAD VALVE ASSEMBLY INSTALLATION ON SOME MODEL COACHES. THE LONGER LIFE VALVES WILL IMPROVE THE DURABILITY OF THE TAG UNLOAD VALVE
SB-3043
Sep 28, 2010
042300 SERVICE BRAKES, AIR:SUPPLY:CHECK VALVE
MCI: TAG UNLOAD VALVE ASSEMBLY. EFFECTIVE WITH UNIT NUMBER 65614, MCI HAS MADE DESIGN CHANGES TO THE TAG UNLOAD VALVE ASSEMBLY INSTALLATION ON SOME MODEL COACHES. THE LONGER LIFE VALVES WILL IMPROVE THE DURABILITY OF THE TAG UNLOAD VALVE
SB-330
Jul 6, 2009
282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT
MOTOR COACH INC.: MCI HAS BECOME AWARE OF FAILURES OF THE SENSORS WHERE THE SYSTEM IS CONSTANTLY SIGNALING AN OBSTRUCTION BEHIND, WHEN NO OBSTRUCTION EXISTS. THE ORIGINAL SENSOR INSTALLED IN THE COACH WAS TOO SENSITIVE AND WOULD SOMETIMES
SB-330
Jul 6, 2009
356000 EQUIPMENT ADAPTIVE/MOBILITY
MOTOR COACH INC.: MCI HAS BECOME AWARE OF FAILURES OF THE SENSORS WHERE THE SYSTEM IS CONSTANTLY SIGNALING AN OBSTRUCTION BEHIND, WHEN NO OBSTRUCTION EXISTS. THE ORIGINAL SENSOR INSTALLED IN THE COACH WAS TOO SENSITIVE AND WOULD SOMETIMES
SB-326C
May 15, 2009
042700 SERVICE BRAKES, AIR:SUPPLY:QUICK RELEASE VALVE
MOTORCOACH INC: ATC/ESC RELAY VALVE ASSEMBLY. THE DEFECT INVOLVES A VALVE THAT IS PART OF THE AUTOMATIC TRACTION CONTROL (ATC) AND ELECTRONIC STABILITY CONTROL (ESC) SYSTEMS FOR THE COACH'S REAR AXLES, AND THE ESC FOR THE FRONT AXLES.
SB-326C
May 15, 2009
042300 SERVICE BRAKES, AIR:SUPPLY:CHECK VALVE
MOTORCOACH INC: ATC/ESC RELAY VALVE ASSEMBLY. THE DEFECT INVOLVES A VALVE THAT IS PART OF THE AUTOMATIC TRACTION CONTROL (ATC) AND ELECTRONIC STABILITY CONTROL (ESC) SYSTEMS FOR THE COACH'S REAR AXLES, AND THE ESC FOR THE FRONT AXLES.
SB-317
Mar 28, 2009
118000 ELECTRICAL SYSTEM:SOFTWARE
MOTORCOACH INC.: AN UPGRADE TO THE SOFTWARE PROGRAM IS REQUIRED ON CERTAIN MC1 E4500 AND J4500 COACHES EQUIPPED WITH ALLISON GEN IV B500 TRANSMISSIONS. MODEL YEARS UNKNOWN. *PE
SB-317
Mar 28, 2009
102000 POWER TRAIN:MANUAL TRANSMISSION
MOTORCOACH INC.: AN UPGRADE TO THE SOFTWARE PROGRAM IS REQUIRED ON CERTAIN MC1 E4500 AND J4500 COACHES EQUIPPED WITH ALLISON GEN IV B500 TRANSMISSIONS. MODEL YEARS UNKNOWN. *PE
SB-3013
Mar 23, 2009
042400 SERVICE BRAKES, AIR:SUPPLY:RESERVOIR/TANK
MCI COACH: REAR RELAY VALVE. THE ISSUE INVOLVES LEAKAGE FROM THE SECONDARY RESERVOIR TO (OR THROUGH, IF THE DRAIN COCK IS LEFT OPEN) THE PRIMARY RESERVOIR WHEN A FULL SERVICE BRAKES APPLICATION IS MADE AFTER THE PRIMARY RESERVOIR HAS BEEN D
SB-3013
Mar 23, 2009
040000 SERVICE BRAKES, AIR
MCI COACH: REAR RELAY VALVE. THE ISSUE INVOLVES LEAKAGE FROM THE SECONDARY RESERVOIR TO (OR THROUGH, IF THE DRAIN COCK IS LEFT OPEN) THE PRIMARY RESERVOIR WHEN A FULL SERVICE BRAKES APPLICATION IS MADE AFTER THE PRIMARY RESERVOIR HAS BEEN D
SB-3012
Mar 23, 2009
061000 ENGINE AND ENGINE COOLING:ENGINE
MCI: ENGINE PAN PROTECTION TUBE ASSEMBLY. MODEL YEARS UNKNOWN. *PE
SB-3007
Mar 2, 2009
052220 PARKING BRAKE:DRIVELINE:AIR:CHAMBER
MOTORCOACH: PRODUCT IMPROVEMENT CHANGE TO THE BRAKE CHAMBERS USED ON THE FRONT AXLE OF E4500/J4500 COACHES HAVING EX225 DISC BRAKES. MODEL YEARS UNKNOWN. *PE UPDATED 7/10/09. *PE
SB-3010
Feb 23, 2009
131000 VISIBILITY:WINDSHIELD
MOTORCOACH: A DESIGN CHANGE TO THE DRIVER'S AND PASSENGER'S WINDSHIELD BLIND INSTALLATION. THIS DESIGN CHANGE WILL MINIMIZE BLIND RATTLE DURING COACH OPERATION. MODEL YEARS UNKNOWN. *PE
SB-3010
Feb 23, 2009
350000 EQUIPMENT
MOTORCOACH: A DESIGN CHANGE TO THE DRIVER'S AND PASSENGER'S WINDSHIELD BLIND INSTALLATION. THIS DESIGN CHANGE WILL MINIMIZE BLIND RATTLE DURING COACH OPERATION. MODEL YEARS UNKNOWN. *PE
SP-7-61
Jan 12, 2009
356000 EQUIPMENT ADAPTIVE/MOBILITY
MOTOR COACH: A POTENTIAL FOR SENSOR FAILURE ON COACHES EQUIPPED WITH REAR SENSING SYSTEM. FAILURE MAY BE ADVISING DRIVERS THAT THERE MAY BE AN OBSTRUCTION WITH THREE (3) FEET OF REAR OF COACH, WHEN THERE MAY NOT BE. MODEL YEARS UNKNOWN.
SP-7-61
Jan 12, 2009
980000 UNKNOWN OR OTHER
MOTOR COACH: A POTENTIAL FOR SENSOR FAILURE ON COACHES EQUIPPED WITH REAR SENSING SYSTEM. FAILURE MAY BE ADVISING DRIVERS THAT THERE MAY BE AN OBSTRUCTION WITH THREE (3) FEET OF REAR OF COACH, WHEN THERE MAY NOT BE. MODEL YEARS UNKNOWN.
SP-7-61
Jan 12, 2009
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MOTOR COACH: A POTENTIAL FOR SENSOR FAILURE ON COACHES EQUIPPED WITH REAR SENSING SYSTEM. FAILURE MAY BE ADVISING DRIVERS THAT THERE MAY BE AN OBSTRUCTION WITH THREE (3) FEET OF REAR OF COACH, WHEN THERE MAY NOT BE. MODEL YEARS UNKNOWN.
SB-315B
Jan 6, 2009
062000 ENGINE AND ENGINE COOLING:COOLING SYSTEM
MOTOR COACH: ENGINE SHUTDOWN/LOW COOLANT SENSOR. DIRECT CURRENT LOW COOLANT SENSOR HAS BECOME PLATED WITH COOLANT CHEMICALS AND NO LONGER SENSES THAT COOLANT LEVEL HAS DROPPED. MODEL YEARS UNKNOWN. *PE
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.
NHTSA Safety Investigations — MCI J4500
Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.
PE20001
Opened: Mar 13, 2020 — Closed: Sep 21, 2020
Supply and return heater hose rupture
By letter dated August 31, 2020, Motor Coach Industries (MCI) notified the Office of Defects Investigation (ODI) of a safety defect that may exist in certain model year (MY) 2017-2020 J4500 vehicles. An ODI review of Early Warning Reporting (EWR) submissions by MCI, on MY 2017-2019 J4500 buses, iden... Read more
MCI J4500 — All Years Overview
Complete safety history for the MCI J4500 across all model years (2001–2026).
192
Total Recalls
4
Total Complaints
1
Investigations
1
Reported Crashes
0
Reported Fires
0
Reported Deaths
MCI J4500 — Year by Year
Compare recalls and complaints across model years. Click any year to see full details.
| Year | Recalls | Complaints | |
|---|---|---|---|
| 2026 | 1 | 0 | View |
| 2025 | 1 | 0 | View |
| 2021 | 5 | 0 | View |
| 2020 | 9 | 0 | View |
| 2019 | 12 | 0 | View |
| 2018 | 13 | 0 | View |
| 2017 | 8 | 0 | View |
| 2016 | 7 | 0 | View |
| 2015 | 10 | 0 | View |
| 2014 | 10 | 0 | View |
| 2013 | 7 | 0 | View |
| 2012 | 7 | 1 | View |
| 2011 | 13 | 0 | View |
| 2010 | 11 | 0 | View |
| 2009 | 11 | 0 | View |
| 2008 | 10 | 0 | View |
| 2007 | 8 | 1 | View |
| 2006 | 8 | 0 | View |
| 2005 | 9 | 0 | View |
| 2004 | 8 | 0 | View |
| 2003 | 9 | 2 | View |
| 2002 (current) | 7 | 0 | |
| 2001 | 8 | 0 | View |