2002 Mci D4500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2002 Mci D4500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
7 recalls name the 2002 Mci D4500. 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 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.
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…
Risk and remedy
Risk
If the coach IS in motion, potential injury to persons and/or damage to other vehicles or property could occur.
Remedy
Mci will provide parts and labor to install free of charge to customers, a ricon designed retrofit kit that includes a spring loaded lock mechanism. the safety recall began on march 31, 2010. owners may contact mci customer service line at 1-800-241-2947.
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.
Risk and remedy
Risk
A short could occur, possibly causing smoke and fire.
Remedy
Mci will notify owners and luminator will repair the buses free of charge. please see luminator's defect report 09e-054. the safety recall began on november 9, 2009. owners may contact luminator at 1-972-516-3033 or mci customer service at 1-800-241-2947.
On certain motor coaches, the boost connector housing can fail over time, exposing the positive and negative terminals.
Risk and remedy
Risk
This could result in the grounding of an unprotected circuit and could lead to a thermal event if not corrected.
Remedy
Customers are being advised to remove the boost connector and discard it. customers will be offered a new design boost connector as an alternative at no cost. the recall began on january 2, 2007. owners may contact mci at 1-800-241-2947.
On certain motor coaches equipped with detroit diesel series 60 engines, the turbocharger compressors can fail.
Risk and remedy
Risk
A fire can result should the turbocharger fail.
Remedy
Detroit diesel IS conducting this recall (please see 06e019000) and will remedy these motor coaches. the engines will be repaired free of charge. Owners may contact detroit diesel at 313-592-3708 or motor coach at 866-624-2622.
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.
Risk and remedy
Risk
As a consequence of this lock up, the functions and systems that are part of the multiplex system will remain at their status immediately prior to the lockup. this could affect the electrical operation of brake lights, turn signals, ignition, instrumentation, etc.
Remedy
Owners will be provided with defroster motor relays equipped with suppression resistors and installation instructions. dealers will also replace the hcnc modules with upgraded modules. owner notification IS expected to begin during april 2002. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact mci at 1-800-241-2947.
Owner complaints
1 complaints
Latest complaints
- Service brakes, air
Defective air brake equipment on mci d4500 buses.*mr if there IS less than 90 pci in the air system there IS an audible buzzer and the hazard light illuminates indicating low air. the emergency brake system does not work until the air pressure IS almost "0" on the manometer on the dashboard. *bf *nm
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- 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.
- 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.
- 10038824Motor coach indudstries: information on replacing the coolant pump that may have a problem.
- 10038195Motor coach industries service campaign: see document search button for owner letter. There may be a harsh downshift, rpm flare, or the transmission may lock.
- 10028745Motor 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.
Every Mci D4500 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.