2008 Mci D4500
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2008 Mci D4500. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
8 recalls name the 2008 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.
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.
Mci has notified nhtsa of a defect in certain model year 2009 d4000 and model year 2008-2010 d4500 and d4505 motor coaches fitted with ricon public use lifts. the restraint belt on these lifts was designed to prevent the lift from moving, unless the tongue of the belt IS fully engaged and latched in the buckle. ricon has discovered, however, that it IS…
Risk and remedy
Risk
The user of the lift could be injured should the lift move without the restraint belt properly buckled.
Remedy
Mci IS working with ricon and ricon will be handling the remedy for this campaign. please see ricon's defect report 09e-060. ricon will provide customers with a warning decal and a dvd-based training aid. the recall IS expected to begin during april 2010. owners may contact ricon customer service at 1-800-322-2884, emailing at www.dmata@wabtec.com.
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 2005-2008 d4000, model year 2005-2009 d4500 and d4505 transit buses, equipped with caterpillar C13 engine and 50DN alternator. The alternator cable may become loose within the cable clamp, which could result in chafing of the alternator cable and possible arcing of the cable wires.
Risk and remedy
Risk
This could result in a fire.
Remedy
Mci will notify owners and replace the alternator cable clamp and related hardware free of charge. the safety recall began on november 30, 2009. owners may contact mci customer service 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.
Motor coach industries (mci) IS recalling 24 my 2008 d4505, d4500, d4000istv motor coaches equipped with trw steering gears, models tas85. these steering gears contain potentially defective sector shafts with an incorrect gear tooth which may interfere with the rack-piston teeth, resulting in a sticking or binding condition.
Risk and remedy
Risk
This condition has the potential to cause the steering gear to stall and restrict the steering turning angle of the vehicle which could result in a vehicle crash.
Remedy
Mci IS working with trw to replace the defective steering gear (please see 07e101). the recall began on february 11, 2008. owners may contact trw at 1-765-429-1768 or mci at 1-204-287-4982.
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.
- Alternator cable chafing
This investigation was prompted by a review of service bulletins provided bymci to the agency. Motor coach industries (mci) submitted a service bulletin/product improvement campaign (#3016) in their 579.5 monthly submission regarding an alternator cable chafing issue on d series coaches equipped with a caterpillar C13…
This investigation was prompted by a review of service bulletins provided bymci to the agency. Motor coach industries (mci) submitted a service bulletin/product improvement campaign (#3016) in their 579.5 monthly submission regarding an alternator cable chafing issue on d series coaches equipped with a caterpillar C13 engine and a 50DN delco alternator. The bulletin reported the cable can chafe against an engine bracket or as a result of movement within the cable clamps.the corrective action IS to install a new cable and support brackets.odi believes that there IS a high risk for a thermal event resulting from alternator cables chafing within the engine compartment.odi places increased emphasis on preventing potential fires involving motor coaches and other vehicles which carry large numbers of passengers.in november2009, mci filed a safety recall (09v-346) outlining theirremedy program to resolve this issue. Mci will install a new cable with a heavy duty terminal that does not have a spiral loom over the cable passing through the cable clamps.also, the new clamp and mounting bracket were changed to better align the cable as it passes through the cable clamp thus preventing a chafing condition. The action taken by mci resolves this investigation.accordingly, this investigation IS closed.
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.
- 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.
- 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.
- 10028691Zf friedrichshafen: tag axle/drive shaft interference-detroit diesel series 60 engine and zf transmission. Experience interference 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.