Problems owners report
Complaints filed with NHTSA about the 2002 MCI D4500, by the system named in each complaint. One complaint can name several.
- Service brakes, air1
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 0 injuries and 0 deaths reported
Recalls in Canada
6 Transport Canada recalls for the 2002 MCI D4500.
| 2026007 15 Jan 2026 | Visual System Issue: On certain buses, the wrong glass may have been installed on the lower front entry door panel. As a result, the glass may not meet certain requirements… |
| 2010067 5 Mar 2010 | Other On certain vehicles, the Ricon wheelchair lift located in baggage bay #2 could become disengaged from a locked position and slide freely. As a secondary mode o… |
| 2009318 9 Nov 2009 | Other On certain buses, the LED sign, mounted to the side of the bus to display destination message, could suffer electronic circuit board corrosion. This could caus… |
| 2008404 12 Nov 2008 | Other On certain motorhomes equipped with a ZF ASTRONIC shift selector there is a potential to malfunction as a result of a cellular phone, PDA, radio interference, i… |
| 2006352 14 Dec 2006 | Electrical On certain coaches, the boost connector's plastic housing may crack, which can allow the positive and negative leads to come in contact. An electrical short co… |
| 2006099 3 May 2006 | Engine On certain coaches equipped with Detroit Diesel 60 series engines, the turbocharger can fail, allowing lubricating oil to enter the exhaust system. This can re… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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. As such, these vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) number 205, "Glazing Materials."
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 subject products for insulation was found to be capable of conducting electricity after being exposed to heat.
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 ROLLERS IN THE STORAGE STRUCTURE, POTENTIALLY BREAKING THROUGH THE CASSETTE DOOR AND EXTENDING BEYOND THE OUTSIDE OF THE DOOR WHEN THE COACH IS IN MOTION, PARTICULARLY WHEN THE COACH IS MAKING A LEFT TURN.
MCI IS RECALLING CERTAIN MODEL YEAR 2002-2009 D SERIES COACHES, EQUIPPED WITH LUMINATOR HORIZON LED SIDE DESTINATION SIGNS. THE CONNECTOR BOARD CAN CORRODE DUE TO AN ACCUMULATION OF MOISTURE UNDER THE CONNECTOR.
ON CERTAIN MOTOR COACHES, THE BOOST CONNECTOR HOUSING CAN FAIL OVER TIME, EXPOSING THE POSITIVE AND NEGATIVE TERMINALS.
ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.
ON CERTAIN MOTOR COACHES THAT HAVE MULTIPLEX SYSTEMS, WHEN THE COACH'S DEFROSTER MOTOR IS ACTIVATED, CERTAIN HIGH SPEED CELL NET CONTROLLERS (HCNC) MAY LOCK UP.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What MCI told its dealers about the 2002 MCI D4500: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10167366 | 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. |
| 10038824 | MOTOR COACH INDUDSTRIES: INFORMATION ON REPLACING THE COOLANT PUMP THAT MAY HAVE A PROBLEM. *RM |
| 10038195 | 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 |
| 10028745 | 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 |
NHTSA manufacturer communications (public domain)
NHTSA investigations
MCI Drive Shaft Safety Loop Failures
MCI Driveshaft Safety Loop Failures
NHTSA Office of Defects Investigation