2020 MCI J4500

9 recalls — 0 complaints — 49 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:MECHANICAL:CARRIER/RACK

Defect Description

Motor Coach Industries (MCI) is recalling certain 2019-2021 D45CRTLE, J3500, and J4500 coaches, equipped with a rear-mounted bike rack. The vehicle's rear lighting may be obstructed when bikes are installed on the bike rack. As such, these vehicles fail to comply with the requirements of Federal M... Read more

Consequence

Obstructed rear lighting may reduce the visibility of the vehicle to other drivers, increasing the risk of a crash.

Remedy

MCI will provide instructions and a kit to add lighting to the rear-mounted bike rack, free of charge. Owner notification letters were mailed August 31, 2023. Owners may contact MCI customer service at 1-800-241-2947.

140 vehicles affected

Manufacturer: Motor Coach Industries

FUEL SYSTEM, DIESEL:FUEL INJECTION SYSTEM:FUEL RAIL

Defect Description

Motor Coach Industries (MCI) is recalling certain 2019-2022 D4000 ISTV, D4500, 2021 D4000, D4520, 2020-2021 D4505, D4005, 2020-2022 D45CRTLE, and 2019-2021 J4500 vehicles equipped with certain Cummins X12 diesel engines. The fuel tubes between the fuel rail and the injectors for cylinders four, fiv... Read more

Consequence

A high pressure fuel leak in the presence of an ignition source can increase the risk of a fire.

Remedy

On engines with 75 miles or less, Cummins dealers will install vibration isolators to the fuel tubes. Engines with more than 75 miles will receive new fuel tubes with vibration isolators. Repairs will be performed free of charge. Owner notification letters were mailed March 11, 2022. Owners may ... Read more

1,125 vehicles affected

Manufacturer: Motor Coach Industries

ELECTRICAL SYSTEM

Defect Description

Motor Coach Industries (MCI) is recalling certain 2018 D4000, 2018-2020 D4005, D4000ISTV, 2017-2020 D4500, D4505, 2018-2021 J3500, 2017-2021 J4500, 2020 D4520, and 2018-2021 D45CRTLE motorcoaches. The Main Distribution Panel (MDP) located within the battery compartment contains a circuit board that... Read more

Consequence

MDP circuit board failure can result in a fire or an unexpected vehicle shutdown, increasing the risk of a crash.

Remedy

MCI Service Centers will remove the MDP and install a new main disconnect and circuit breaker panel, free of charge. Owner notification letters were mailed November 12, 2021. Owners may contact MCI's customer service at 1-800-241-2947. MCI's number for this recall is R21-010.

2,455 vehicles affected

Manufacturer: Motor Coach Industries

FUEL SYSTEM, DIESEL:FUEL INJECTION SYSTEM:FUEL RAIL

Defect Description

Motor Coach Industries (MCI) is recalling certain 2017-2018 D4000, 2017-2019 D4005, D4000ISTV, D4505, 2017-2020 D4500, J4500, 2018-2020 D45CRTLE, and 2018-2021 J3500 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.

Consequence

A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy

Dealers will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is R21-009.

1,845 vehicles affected

Manufacturer: Motor Coach Industries

ELECTRICAL SYSTEM:12V/24V/48V BATTERY:CABLES

Defect Description

Motor Coach Industries (MCI) is recalling certain 2018-2021 J4500 and 2018-2020 D45CRTLE vehicles. The power cables may have been improperly installed and routed in the vehicle battery compartment, which may result in chafing.

Consequence

The power cables may chafe, increasing the risk of a fire.

Remedy

MCI will notify owners, and dealers will inspect and if necessary, correct the clearance for the power cables in the battery compartment, free of charge. The recall began March 12, 2021. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is R21-003.

1,229 vehicles affected

Manufacturer: Motor Coach Industries

ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

Defect Description

Motor Coach Industries (MCI) is recalling certain 2017-2020 J4500 motor coaches. The coolant hose may fail, resulting in a low coolant warning followed by an engine shut down sequence, as well as the potential for engine coolant spilling on the roadway.

Consequence

The spilled coolant may increase the risk of a crash. Additionally, transferring passengers from the disabled bus can increase their risk of injury.

Remedy

MCI will notify owners, and dealers will replace the coolant hose, free of charge. The recall began October 30, 2020. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this recall is SB 486.

1,561 vehicles affected

Manufacturer: Motor Coach Industries

ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

Defect Description

Motor Coach Industries (MCI) is recalling certain 2018-2020 D4000, D4005, D4500, D4505 and D45CRTLE buses manufactured with electric cooling fans (E-fan) for the radiator and charge air cooler, Borg Warner 55SI model dual alternator configuration (with a sense stud and wire), and Parker Vansco Multi... Read more

Consequence

If the engine shuts down or loses power while the vehicle is in motion, this may increase the risk of a crash.

Remedy

MCI will notify the affected owners, and dealers will install a new application code in the Parker VMM multiplex modules increasing the overvoltage threshold limit, free of charge. The recall began July 23, 2020. Owners may contact MCI customer service at 1-800-241-2947. MCI's number for this rec... Read more

1,067 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

No complaints found for this vehicle.

Technical Service Bulletins — 2020 MCI J4500

49 manufacturer communications from 32 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
350000 EQUIPMENT	14
110000 ELECTRICAL SYSTEM	11
060000 ENGINE AND ENGINE COOLING	8
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER	3
020000 SUSPENSION	2
160000 STRUCTURE	2
080000 FUEL SYSTEM, DIESEL	2
980000 UNKNOWN OR OTHER	1

110000 ELECTRICAL SYSTEM

Instruction to Service ITS60877 provides instructions to relocate an impact sensor in baggage bay to reduce nuisance activations.

110000 ELECTRICAL SYSTEM

Instructions to improve sealing in the front junction box.

160000 STRUCTURE

Instructions to improve sealing in the front junction box.

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

160000 STRUCTURE

Technical Service Information Bulletin describing the retrofit for the front junction box cover on specifically equipped buses.

350000 EQUIPMENT

This Technical Instruction is a description of the inspections and cleaning procedures being recommended by MCI due to the parts shortages which are impacting the repair inspections associated with NHTSA Recall 21V-748. These are the same i

110000 ELECTRICAL SYSTEM

080000 FUEL SYSTEM, DIESEL

This Technical Service Information Bulletin is a supplemental reminder to all MCI owners/operators of vehicles which are affected by the Cummins Equipment Recall 21E-099 and MCI Vehicle recall 21V-971.

060000 ENGINE AND ENGINE COOLING

350000 EQUIPMENT

This Instruction to Service (ITS) is a description of the inspections being recommedned by MCI due to the parts shortages which are impacting the repair instructions associated with NHTSA Recall 21V-748. These are the same instructions as o

110000 ELECTRICAL SYSTEM

350000 EQUIPMENT

This is an upgrade to Technical Service Information Bulletin TSIB 21-10 issued in January of 2022 which is specific to buses operating in severe duty and or corrosive environments. These bulletins have been issued to recommend interim inspe

110000 ELECTRICAL SYSTEM

This Technical Service Information Bulletin describes interim inspection procedures required every 6000 miles on specific motor coaches due to the global parts shortage and subsequent delay in available parts to conduct the corrective actio

350000 EQUIPMENT

220000 SEATS

Technical Service Information Bulletin describing an update to the Preventaive Maintenance requirements for specifically equipped motor coaches with Kiel Avane model passenger seats.

060000 ENGINE AND ENGINE COOLING

This Technical Sevice Information Bulletion is to advise of a part number supersession of the coolant hump hose, MCI PN 6L-8-353, to MCI PN 06-08-2262.

080000 FUEL SYSTEM, DIESEL

Technical instruction describing how to replace the plastic fuel tank filler neck gasket.

060000 ENGINE AND ENGINE COOLING

This service bulletin outlines the steps to add the secondary air filter. The secondary filter can only be used with primary air filter, MCI P/N: 09-03-1858.

350000 EQUIPMENT

This service bulletin outlines the steps to add the secondary air filter. The secondary filter can only be used with primary air filter, MCI P/N: 09-03-1858.

110000 ELECTRICAL SYSTEM

This Service Bulletin informs affected owners of the steps to remove the unused Saucon provisional connector, MCI P/N 19-11-2941, located in the front junction box on coaches without a Saucon telematics module.

350000 EQUIPMENT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

This Service Bulletin informs affected owners that the A/C compressor on certain J4500 coaches are making excessive noise and vibration which may result in vibration transferred to the coach frame, possibly resulting in noise and passenger

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 affected owners that on certain D45CRTLE and J4500 model coaches equipped with Cummins X12 engines, the top alternator power and ground cables may potentially come in contact with the edge of the clamp mounting

060000 ENGINE AND ENGINE COOLING

This service bulletin advises owners of affected vehicles that Mobile Climate Control ("MCC") has notified MCI that certain new style evaporator motors supplied by MCC may have inadequate electrical contacts at the main circuit board, which

110000 ELECTRICAL SYSTEM

350000 EQUIPMENT

060000 ENGINE AND ENGINE COOLING

This service bulletin advises owners of affected vehicles that Modine Manufacturing Co. has notified MCI that some of the e-fan engine cooling modules may have their harness rubbing on an uncovered metal edge, which could lead to harness da

110000 ELECTRICAL SYSTEM

356000 EQUIPMENT ADAPTIVE/MOBILITY

180000 VEHICLE SPEED CONTROL

This service bulletin advises owners of affected vehicles that the throttle pedal sensors may provide intermittent, erratic data and cause the "engine check" light to become illuminated, and how repairs can be made to correct the vehicles.

350000 EQUIPMENT

This service bulletin outlines the steps to relocate the ambient temperature sensor from the spare tire compartment to the bumperette to improve the accuracy of the sensor reading. This service bulletin needs to be done in conjunction with

040000 SERVICE BRAKES, AIR

This service bulletin advises owners of affected vehicles that ZF has notified MCI that some brake chambers installed on the ZF drive axle have had water ingress, causing malfunction of the pneumatic brake system and dragging brakes during

020000 SUSPENSION

This service bulletin outlines the steps to replace the adapter plates on the tag axle bellows to increase support for the bellow piston.

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.

060000 ENGINE AND ENGINE COOLING

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

This Procedure outlines the steps to space out the condenser discharge and heater coolant lines.

060000 ENGINE AND ENGINE COOLING

This Procedure outlines the steps to space out the condenser discharge and heater coolant lines.

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

This Procedure outlines steps to replace the double groove belt on the A/C Compressor with single groove matched belts.

350000 EQUIPMENT

This Procedure outlines steps to replace the double groove belt on the A/C Compressor with single groove matched belts.

350000 EQUIPMENT

This Service Bulletin outlines the steps to install reinforcement bracket for the mudflap on coaches equipped with MCI P/N 03-33-2646.

010000 STEERING

This Service Bulletin outlines the necessary steps to inspect the power steering system for proper operation. It also lists the necessary steps to replace the power steering seals if needed.

130000 VISIBILITY

This Procedure outlines steps to add mechanical fasteners to the dual lock tape retaining the rear window trim panel.

060000 ENGINE AND ENGINE COOLING

This Service Bulletin advises customers facing issues with a low engine oil pan protector profile how to replace it with a new model with higher ground clearance.

350000 EQUIPMENT

This Service Bulletin informs owners of model year 2018-2020 J3500 and J4500 model coaches of the procedure to insulate the gap in the area between the front cap and under the dash panel on the driver's side, that will help shield the ambie

350000 EQUIPMENT

This Procedure outlines the steps to inspect and adjust ground clearance setting.

020000 SUSPENSION

This Service Bulletin informs owners of model year 2018-2020 J4500 model coaches hearing noise near the front sway bar during driving to apply anti-seize lubricant per the instructions.

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.

PE — Closed — Model Year: 2017

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 (current)	9	0
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	7	0	View
2001	8	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