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2002 Mci D4500 Recalls

Recalls on record Updated July 2026

The 2002 Mci D4500 has 7 NHTSA recall campaigns affecting an estimated 37,310 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 1 complaint with NHTSA, most often about the service brakes, air. Last updated July 5, 2026.

Recall campaigns

VISIBILITY 25V853000 2025-12-10 15,454 affected
Defect

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…

Consequence

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.

ELECTRICAL SYSTEM 13V498000 2013-10-17 10,016 affected
Defect

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…

Consequence

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.

EQUIPMENT ADAPTIVE/MOBILITY 10V087000 2010-03-09 4,457 affected
Defect

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…

Consequence

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.

INTERIOR LIGHTING 09V432000 2009-11-03 701 affected
Defect

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.

Consequence

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.

ELECTRICAL SYSTEM 06V481000 2006-12-19 1,617 affected
Defect

ON CERTAIN MOTOR COACHES, THE BOOST CONNECTOR HOUSING CAN FAIL OVER TIME, EXPOSING THE POSITIVE AND NEGATIVE TERMINALS.

Consequence

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.

ENGINE AND ENGINE COOLING 06V140000 2006-04-27 4,765 affected
Defect

ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.

Consequence

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.

ELECTRICAL SYSTEM 02V103000 2002-04-04 300 affected
Defect

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.

Consequence

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…

Complaints by component

SERVICE BRAKES, AIR
1
Total complaints1

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“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”

SERVICE BRAKES, AIR · reported 1901-01-01

Defect investigations

Investigation EA12007 Opened 2012-09-13 · closed 2015-12-03

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…

Investigation EA12007 Opened 2012-09-13 · closed 2015-12-03

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…

Investigation EA12007 Opened 2012-09-13 · closed 2015-12-03

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…

Investigation PE12007 Opened 2012-03-21 · closed 2012-09-20

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.…

Investigation PE12007 Opened 2012-03-21 · closed 2012-09-20

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.…

Investigation PE12007 Opened 2012-03-21 · closed 2012-09-20

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.…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2002 Mci D4500 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.