2012 Mci D4005
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Recalls
7 recalls name the 2012 Mci D4005. Newest first.
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…
Risk and remedy
Risk
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.
Motor Coach Industries (MCI) is recalling certain 2011-2016 D4500, D4505, D4000, D4005, and D4000 ISTV motor coaches equipped with ISX engines. Due to vibrations, the exhaust bellow pipes develop a hole.
Risk and remedy
Risk
If the pipe develops a hole, during a regeneration cycle, hot exhaust gases may leak out, increasing the risk of a fire.
Remedy
MCI will notify owners, and dealers will replace the bellows pipe assembly with an improved part, free of charge. The recall began July 10, 2018. Owners may contact MCI customer service at 1-800-241-2947.
Motor Coach Industries (MCI) is recalling certain 2011-2012 MCI D4000, D4005, D4500 and D4505 coaches equipped with Cummins ISX 12 liter engines. The vehicles may have an incorrectly installed exhaust bellow pipe, resulting in a bend in the pipe which can cause its premature failure.
Risk and remedy
Risk
If the pipe fails and a diesel regeneration cycle occurs, the hot exhaust gases will increase the risk of a fire.
Remedy
MCI will notify owners and dealers will inspect and replace any deformed or failed bellow pipes if necessary, free of charge. The recall began on June 15, 2017. Owners may contact Motor Industries at 1-800-241-2947. MCI's number for this recall is SB 397B.
Motor Coach Industries (MCI) is recalling certain model year 2011-2013 and 2015 J4500 coaches manufactured November 18, 2011, to July 10, 2015, 2011-2012 and 2014-2015 D4000 coaches manufactured manufactured September 24, 2010, to September 5, 2015, 2011-2013 and 2015-2016 D4005 coaches manufactured January 17, 2011, to November 23, 2015, 2012-2014 and 2016…
Risk and remedy
Risk
If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.
Remedy
MCI will notify owners and dealers will inspect the seats and determined if welds are missing. Any J-Bracket that is missing welds will be removed and replaced, free of charge. The recall began on February 15, 2016. Owners may contact MCI at 1-800-241-2947. MCI's number for this recall is SB 431.
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…
Risk and remedy
Risk
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.
Motor Coach Industries (MCI) is recalling certain model year 2012-2013 D4000, D4000ISTV, D4005, D4500, and D4505 motorcoaches manufactured from May 2012 through December 2012 and equipped with a Cummins ISX EPA 2010 engine. In the affected buses, the bellows pipe in the exhaust system may have been incorrectly assembled, which could result in a failure of…
Risk and remedy
Risk
During a regeneration process to clean exhaust emissions, if the bellows pipe has failed, the hot exhaust gases may not be contained, resulting in a fire.
Remedy
MCI will notify owners and dealers will inspect and replace the bellows pipes, as necessary, free of charge. The recall began on April 29, 2013. Customers may contact MCI at 1-847-285-2000.
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…
Risk and remedy
Risk
If the driver IS slow to react during this esc intervention, the vehicle may deviate from the intended line of travel, increasing the risk of a crash.
Remedy
Mci will notify owners and replace the control module free of charge. the safety recall began on january 4, 2012. owners may contact mci customer service at 1-800-241-2947.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Exhaust Bellows Pipe Fracture Recall
By letter dated April 15, 2013, Motor Coach Industries (MCI) notified the Office of Defects Investigation (ODI) of a safety defect that may exist in certain model year (MY) 2012 and 2013 MCI D-model coaches built from December 22, 2011 to May 19, 2012 equipped with the Cummins 2010 EPA ISX 12 Liter engine.These…
By letter dated April 15, 2013, Motor Coach Industries (MCI) notified the Office of Defects Investigation (ODI) of a safety defect that may exist in certain model year (MY) 2012 and 2013 MCI D-model coaches built from December 22, 2011 to May 19, 2012 equipped with the Cummins 2010 EPA ISX 12 Liter engine.These vehicles may have had an incorrect installation of the exhaust pipe.If installed incorrectly, the elbow pipe may prematurely fail and if a Diesel Particulate Filter regeneration event occurs, the hot exhaust gases could cause a fire, resulting in injury to persons and/or damage to property.MCI conducted an inspect and repair if necessary recall campaign identified by NHTSA Recall No: 13V-142. At the time MCI believed that 13V-142 covered all the vehicles potentially having the safety defect. However, ODI review of EWR data indicated that other vehicles outside the scope of 13V-142 also experienced the same defect condition. Subsequently, in May 2017, MCI expanded the scope of the previous recall to include certain MY 2011-2012 MCI D-model coaches manufactured from January 31, 2011 to May 19, 2012, identified by NHTSA Recall No: 17V-337.In April 2013 when MCI conducted recall 13V-142 to remedy incorrectly installed bellows pipes on certain MCI model year 2012 and 2013 D model vehicles they also changed the bellows pipe assembly process in then current production.With recall 17V-337 MCI expanded the first recall by an additional 178 vehicles they felt also had not had the bellows pipe properly installed.Following the receipt of complaints and EWR data alleging bellows pipe failures on vehicles built after the implementation of the improved assembly process, NHTSA opened this Recall Query to assess the scope and adequacy of these two safety recalls and MCI's recall decision making process.Analysis of the failure data provided by MCI to this investigation found that the improved assembly process reduced the failure rate but did not eliminate the defect all together.In response to this investigation, MCI agreed to conduct recall 18V-309. This latest recall includes and expands upon the vehicle population of the prior recalls, and implements a new remedy that adds a mesh component to the bellows assembly to reduce vibration.This remedy was also implemented in production in 2015.Vehicles built after this date do not have an elevated failure rate even with a significant amount of time in service.With recall action 18V-309 taken by MCI this investigation is closed. Further use of agency resources does not appear to be warranted. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist on other model or MY vehicles outside of the recall scope. The agency reserves the right to take further action if warranted by the circumstances.
- MCI Drive Shaft Safety Loop Failures
In the fall of 2011, network contacts made ODI aware of four (4) incidents of drive shaft failure on the subject buses involving a loss of vehicle control.Two of the incidents were relatively low speed non-crash events; and two resulted in motor coach rollovers.All four events showed signs of a common failure mode.The…
In the fall of 2011, network contacts made ODI aware of four (4) incidents of drive shaft failure on the subject buses involving a loss of vehicle control.Two of the incidents were relatively low speed non-crash events; and two resulted in motor coach rollovers.All four events showed signs of a common failure mode.The incidents and crashes studied during this investigation all resulted from a series of complex events that began with the the yoke journal ears on the drive shafts fracturing.Once the drive shaft failed. it was not adequately contained by a drive shaft safety loop or structure.The spinning and unrestrained drive shaft caused severe damage to components on the steerable tag axle at the rear of the vehicle and created a forced steering condition.Once the rear of the bus was being forcibly steered by the tag axle, the driver lost control of the vehicle.These conclusions are based on the forensics evidence and testing conducted by the Vehicle Research and Test Center (VRTC).The VRTC test report is attached to this closing resume that provides details on how the test center was able to conclusively identify the defective components on the buses and demonstrate the sequence of events that caused the buses to crash.Prior to the drive shaft failure events, there were no indications of improper maintenance or that maintenance was required that would have prevented the incidents.Additionally, the U-joints on the incident vehicles were found to be in good working condition at the time of the failure. Finally, records of driver interviews indicated a sudden onset of the failure with no warning.Following the VRTC testing, MCI issued recall 14V-335 involving certain model year 1993-1995 102DL3 motor coaches manufactured November 1992 to January 1995, and 2006 and 2008 D4505 motor coaches manufactured June 2005 to April 2008.The affected buses are equipped with a drive shaft with a compressed length of 30 inches or less (allowing it to escape containment if it fails), a steerable trailing tag axle equipped with a system that changes the axle caster when the vehicle is in reverse travel and no electronic stability control (ESC).Recall 14V-335 addresses the concerns of this investigation.The ODI report cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID: ODI Number 10447575.
- MCI Driveshaft Safety Loop Failures
ODI has identified certain MCI coaches with powertrain configurations that may allow a driveshaft separated at the rearward universal joint to escape the guardian structure of the steerable tag axle and damage steering and braking components.The damaged components may increase the risk of a loss of vehicle control.…
ODI has identified certain MCI coaches with powertrain configurations that may allow a driveshaft separated at the rearward universal joint to escape the guardian structure of the steerable tag axle and damage steering and braking components.The damaged components may increase the risk of a loss of vehicle control. The subject coaches include 806 model year 1992 through 2012 MCI D and E series motor coaches with steerable tag axles.This Preliminary Evaluation is being upgraded to an Engineering Analysis (EA12-007) to further study the alleged defect and to determine if a safety defect exists. The ODI report cited above can be viewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID: ODI Number 10447575.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 11011092Information to owners showing the proper procedure for checking the oil level in a BITZER HVAC compressor.
- 10213033Technical Service Information Bulletin describing the replacement of seating backrest attachment hardware with the addition of a mechanical lock nut on specifically equipped buses manufactured prior to model year 2020.
- 10206198This Technical Service Information Bulletin (TSIB) describes an update from Meritor for the bolt torque application requirements on hub-to-rotor bolts for the front, drive and tag axles, on specific coaches equipped with Meritor EX225 disc brakes, on either Conventional, PreSet or Unitized Wheel-End hubs.
- 10180805This 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.
- 10167381This Procedure outlines the steps to install a relief valve on the air compressor for coaches equipped with DD13 engines.
- 10167366This Service Bulletin informs owners of the procedure to clean the batteries and reapply corrosion inhibitor every 6000 miles or 3 months, whichever first occurs.
- 10119746This Service Bulletin supersedes Service Bulletin 424 in its entirety and informs customers that MCI was notified by Cummins Inc. that it has issued a campaign to addresses the ISX lubricating oil filter bypass valve in addition to the previous fuel pump repair with a new bypass valve that has more effective sealing capability and provides better protection to fuel pump lubricated components on model year 2008-2013 MCI D model coaches and model year 2011-2014 MCI J4500 model coaches. This program is being performed only by Cummins Service Network and its authorized dealers, therefore, all parts and labor required for this program will be provided by Cummins.
- 10119743This Service Bulletin informs customers that MCI was notified by Cummins Inc. that it has released Campaign C1638 that addresses the ISX lubricating oil filter bypass valve in addition to the previous fuel pump repair actions outlined in MCI SB 419 and Cummins FCP C1556 on model year 2008-2013 MCI D model coaches and model year 2011-2014 MCI J4500 model coaches. This program is being performed only by Cummins Service Network and its authorized dealers, therefore, all parts and labor required for this program will be provided by Cummins.
- 10119169This Service Bulletin informs affected customers that MCI was notified by Cummins Inc. that it has issued a campaign to address ISX high pressure fuel pump ceramic plunger fractures as well as the potential of damage to the roller/tappet assembly on model year 2011-2013 MCI D model coaches and model year 2011-2014 MCI J4500 model coaches. This program is being performed only by Cummins Service Network and its authorized dealers, therefore, all parts and labor required for this program will be provided by Cummins.
- 10119162This Service Bulletin informs affected customers that the diesel exhaust fluid (DEF) pressure line may exhibit signs of fatigue and melting on model year 2011-2013 MCI D model coaches, and that MCI will remedy the affected coaches at no cost to the customers.
- 10119152This Service Bulletin supersedes Service Bulletin 392 in its entirety and informs affected customers that coaches equipped with a Cummins 2010 engine can experience intermittent faults of the engine and/or transmission of the mulitplex controller program and as a result, the coach will operate with active engine and/or transmission codes that may require immediate attention on model year 2011-2013 MCI D model coaches, and that MCI will remedy the affected coaches at no cost to the customers.
- 10119150This Service Bulletin informs customers that MCI was notified by Cummins Inc. that it has released Campaign C1344 that addresses a calibration change, which Cummins advises will improve the engine and aftertreatment reliability on Cummins ISX engines in model year 2011-2013 MCI D model coaches, model year 2011-2013 MCI E4500 model coaches and model year 2011-2013 MCI J4500 model coaches. This program is being performed only by Cummins Service Network and its authorized dealers, therefore, all parts and labor required for this program will be provided by Cummins.
- 10119143This Service Bulletin informs affected customers that MCI was notified by Cummins Inc. that it has issued campaign C1241 that addresses a calibration issue, which results in the engine brakes being energized with 24 volts rather than the required 12 volts on Cummins ISX engines in model year 2011-2012 MCI D model coaches, model year 2011-2012 MCI E4500 model coaches, and model year 2011-2012 MCI J4500 model coaches. This program is being performed only by Cummins Service Network and its authorized dealers, therefore, all parts and labor required for this program will be provided by Cummins.
- 10119139This Service Bulletin informs affected customers that the retention nut utilized on the Leece Neville alternator pulley installation is not maintaining the proper torque which may result in alternator bearing failure on model year 2011-2012 MCI D model coaches, 2011-2012 MCI E4500 model coaches, and 2011-2012 MCI J4500 model coaches, and that MCI will remedy the affected coaches at no cost to the customers.
- 10056066Motor coach industries (mci): red 185 durometer polyurethane bushings were replaced with 288 polyurethane bushings in shock absorbers that in cold temperatures, will fail, causing absorber stud to break, at bushing, and coach IS not operational due to risk of damage to suspension component. Model d series.
Every Mci D4005 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.