The defect
Motor Coach Industries (MCI) is recalling certain 2020-2021 J4500E, 2021 D45CRTELE, 2023 J4500E, 2023-2024 D45CRTELE, 2024 D45CRTE, and 2025 J4500E buses. An inadequate weld on the high voltage battery busbar and incorrect software may cause the battery module to overheat.
The risk
A battery module that overheats increases the risk of a fire.
The remedy
MCI will inspect and replace the battery module as necessary. MCI will also update the BMS software. Owner notification letters were mailed October 6, 2025. Owners may contact MCI customer service at 1-800-241-2947.
NHTSA's own wording · initiated by MFR
Vehicles covered
| Model | Model years |
|---|---|
| MCI D45CRTE | 2024 |
| MCI D45CRTELE | 2021, 2023, 2024 |
| MCI J4500E | 2020, 2021, 2023, 2025 |
Components: ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY | ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| MCI D45CRTE | 2024 | 0 | 3 |
| MCI D45CRTELE | 2021 | 0 | 3 |
| MCI D45CRTELE | 2023 | 0 | 2 |
| MCI D45CRTELE | 2024 | 0 | 2 |
| MCI J4500E | 2020 | 0 | 1 |
| MCI J4500E | 2021 | 0 | 1 |
| MCI J4500E | 2023 | 0 | 1 |
| MCI J4500E | 2025 | 0 | 2 |
Other electrical system recalls in 2025
148 of the 891 recall campaigns reported to NHTSA in 2025 concerned the electrical system; Motor Coach Industries filed 45 campaigns in all.
| 25V914000 31 Dec 2025 | Braun Industries, Inc. |
| 25V906000 23 Dec 2025 | BMW of North America, LLC |
| 25V911000 23 Dec 2025 | Honda (American Honda Motor Co.) |
| 25V905000 23 Dec 2025 | Tiffin Motorhomes, Inc. |
| 25V897000 19 Dec 2025 | Blue Bird Body Company |
| 25V895000 19 Dec 2025 | Coach and Equipment Mfg. Corp. |
| 25V894000 19 Dec 2025 | Mercedes-Benz USA, LLC |
| 25V886000 18 Dec 2025 | Ford Motor Company |
NHTSA recalls (public domain) · all recalls of 2025