Problems owners report
Complaints filed with NHTSA about the 2003 MCI E4500, by the system named in each complaint. One complaint can name several.
- Electrical system1
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 0 injuries and 0 deaths reported
Recalls in Canada
7 Transport Canada recalls for the 2003 MCI E4500.
| 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… |
| 2019006 8 Jan 2019 | Steering Issue: Certain buses built with a rear tag-axle steering system may exhibit a steering lock-up at highway speed. Safety Risk: This problem could cause a… |
| 2011377 21 Oct 2011 | Other On certain vehicles, specific operating conditions (such as tight, successive, highly banked curves in opposite directions), could trigger unintended Electronic… |
| 2010270 11 Aug 2010 | Structure On certain buses, the adhesive bond between the window glass assembly and the aluminum window frame may degrade. If the adhesive bond degrades (also known as d… |
| 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… |
| 2006173 17 Jul 2006 | Electrical On certain vehicles, the Carrier Pulse Width Modulator (PWM) speed controller may fail and cause the fan motor to operate continuously in the "HIGH" speed mode,… |
| 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 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 steering control at highway speeds.
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.
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 2011. UNDER CERTAIN ROAD AND DRIVING CONDITIONS, VEHICLE BODY ROLL AND ROAD INCLINATION CHARACTERISTICS MAY ADVERSELY AFFECT THE SLIP ANGLE CALCULATION OF THE ELECTRONIC STABILITY CONTROL (ESC) SYSTEM. THIS MIGHT CAUSE THE ESC TO PERCEIVE AN OVER STEERING SITUATION AND THEREFORE APPLY THE OUTER WHEEL BRAKE ON THE FRONT AXLE UNTIL THE VEHICLE IS PERCEIVED TO BE STABLE.
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.
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; 2009 E4500 COACHES MANUFACTURED BETWEEN JANUARY AND APRIL 2009; AND ONE 2003 E4500 COACH MANUFACTURED IN OCTOBER 2002. THESE VEHICLES MAY HAVE BEEN EQUIPPED WITH MERITOR WABCO STEERING ANGLE SENSORS (SAS) WHICH CAN DEVELOP INTERNAL FRICTION BETWEEN THE SENSOR GEARS AND THE SENSOR HOUSING AS A RESULT OF EXTERNAL FORCES EXPERIENCED ON THE VEHICLE INCLUDING VIBRATION. IF DEVELOPED FRICTION IS GREAT ENOUGH, THE DRIVING TAB OF THE SAS CAN SHEER AS THE DRIVER TURNS THE STEERING WHEEL.
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.
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 FAIL TO REDUCE OR OTHERWISE CONTROL THE FAN MOTOR SPEED.
ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.
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 2003 MCI E4500: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10194925 | 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 windows for de-bonding as indicated in the maintenance manual, and repair if necessary in accordance with that Service Bulletin. |
| 10152973 | 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 caster, if necessary. |
| 10119144 | 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 result in potential vacuum issues which could result in collapsing of the tank walls on MCI D model coaches, MCI E4500 model coaches and MCI J4500 model coaches. |
| 10045859 | 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. *PE UPDATED 12/10/12. *PE |
| 10042911 | 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 |
| 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 |
| 10034486 | 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 ASSEMBLY. MODELS E4500/J4500 SERIES. NO MODEL YEARS LISTED. *PE |
| 10030906 | 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 SENSE THE REAR BUMPER AS AN OBSTRUCTION. *PE |
| 10029485 | 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 |
| 10029346 | MCI: ENGINE PAN PROTECTION TUBE ASSEMBLY. MODEL YEARS UNKNOWN. *PE |
| 10028747 | 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. *PE |
| 10028708 | 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 |
| 10028706 | 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 |
NHTSA manufacturer communications (public domain)
NHTSA investigations
MCI Drive Shaft Safety Loop Failures
NHTSA Office of Defects Investigation