MCI D4000 recalls
Every NHTSA recall campaign filed since 2000 that names the MCI D4000, newest first. Last verified Jul 30, 2026.
Units are totals reported across campaigns mentioning this model — NHTSA does not always break unit counts down by model.
Affected components
Recalls by model year
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →All campaigns
- Dec 10, 2025Crash risk1988–2001 MCI 102D3, 2000–2001 MCI 102D3ISTV, 1988–2001 MCI 102DL3 and 9 other models — Visibility
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 Vehicle Safety Standard (FMVSS) number 205, "Glazing Materials."
25V853000 · 15K units · Motor Coach Industries, Inc
- Feb 7, 2024Crash risk2014–2018 MCI D4000, 2013–2019 MCI D4005, 2013–2023 MCI D4500 and 2 other models — Equipment Adaptive/mobility
Motor Coach Industries (MCI) is recalling certain 2014-2018 D4000, 2013-2019 D4005, 2013-2023 D4500, 2013-2020 D4505, and 2021-2024 D45CRT coaches equipped with a Ricon wheelchair lift. The red beacon lighting on the Threshold Warning System (TWS) may not be bright enough. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 403, "Platform Lift Systems."
24V073000 · 2K units · Motor Coach Industries
- Dec 15, 2021Fire risk2021 MCI D4000, 2019–2022 MCI D4000 Istv, 2020–2021 MCI D4005 and 5 other models — Fuel System, Diesel
Motor Coach Industries (MCI) is recalling certain 2019-2022 D4000 ISTV, D4500, 2021 D4000, D4520, 2020-2021 D4505, D4005, 2020-2022 D45CRTLE, and 2019-2021 J4500 vehicles equipped with certain Cummins X12 diesel engines. The fuel tubes between the fuel rail and the injectors for cylinders four, five, and six may fatigue and crack, which can result in a high pressure fuel leak.
21V971000 · 1K units · Motor Coach Industries
- Sep 24, 2021Fire risk2018 MCI D4000, 2018–2020 MCI D4000ISTV, 2018–2020 MCI D4005 and 6 other models — Electrical System
Motor Coach Industries (MCI) is recalling certain 2018 D4000, 2018-2020 D4005, D4000ISTV, 2017-2020 D4500, D4505, 2018-2021 J3500, 2017-2021 J4500, 2020 D4520, and 2018-2021 D45CRTLE motorcoaches. The Main Distribution Panel (MDP) located within the battery compartment contains a circuit board that may fail.
21V748000 · 2K units · Motor Coach Industries
- May 18, 2021Fire risk2017–2018 MCI D4000, 2017–2019 MCI D4000ISTV, 2017–2019 MCI D4005 and 5 other models — Fuel System, Diesel
Motor Coach Industries (MCI) is recalling certain 2017-2018 D4000, 2017-2019 D4005, D4000ISTV, D4505, 2017-2020 D4500, J4500, 2018-2020 D45CRTLE, and 2018-2021 J3500 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.
21V364000 · 2K units · Motor Coach Industries
- Jun 12, 2020Crash risk2018–2020 MCI D4000, 2018–2020 MCI D4005, 2018–2020 MCI D45 CRT LE and 3 other models — Electrical System
Motor Coach Industries (MCI) is recalling certain 2018-2020 D4000, D4005, D4500, D4505 and D45CRTLE buses manufactured with electric cooling fans (E-fan) for the radiator and charge air cooler, Borg Warner 55SI model dual alternator configuration (with a sense stud and wire), and Parker Vansco Multiplexing Module (VMM) Multiplex system. A build-up of debris, corrosion, and/or water flow could cause a high resistance path to ground for the sense stud on the back of the alternator and cause the alternator to produce excessive voltage output, which may exceed the threshold limit currently programmed in the VMM and result in a loss of engine power and vehicle shutdown.
20V352000 · 1K units · Motor Coach Industries
- Apr 29, 2020Crash risk2015–2016 MCI D4000, 2017 MCI D4005, 2015–2020 MCI D4500 and 3 other models — Seat Belts
Motor Coach Industries (MCI) is recalling certain 2015-2016 D4000, 2015-2020 D4500 and D4505, 2016-2020 J4500, 2018 J3500, and 2017 D4005 buses. The seat belts may not extend from the retracted position, rendering the seat belt unusable. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standards (FMVSS) number 208, "Occupant Crash Protection," and number 209, "Seat Belt Assemblies."
20V242000 · 641 units · Motor Coach Industries
- May 13, 2018Fire risk2012–2016 MCI D4000, 2012–2015 MCI D4000ISTV, 2012–2016 MCI D4005 and 2 other models — Engine and Engine Cooling
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.
18V309000 · 1K units · Motor Coach Industries
- May 24, 2017Fire risk2011–2012 MCI D4000, 2011–2012 MCI D4005, 2011–2012 MCI D4500 and 1 other model — Engine and Engine Cooling
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.
17V337000 · 143 units · Motor Coach Industries
- Jan 20, 2016Crash risk2011–2015 MCI D4000, 2012–2016 MCI D4000ISTV, 2011–2016 MCI D4005 and 3 other models — Seats
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 D4000ISTV coaches manufactured July 18, 2012, to December 2, 2015, 2010-2016 D4500 coaches manufactured April 15, 2010, to December 18, 2015 and 2011-2016 D4505 coaches manufactured December 15, 2010, to December 4, 2015. The affected buses are equipped with certain Recaro Ergo-M Commercial Bus Driver Seats that have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.
16V020000 · 607 units · Motor Coach Industries
- Sep 21, 2015Fire risk2015 MCI D4000, 2015 MCI D4005, 2015 MCI D4500 and 1 other model — Electrical System
Motor Coach Industries, Inc. (MCI) is recalling certain model year 2015 D4000 vehicles manufactured June 8, 2015, to July 20, 2015, D4005 vehicles manufactured March 18, 2015, to July 10, 2015, D4500 vehicles manufactured December 19, 2014, to July 20, 2015, and D4505 vehicles manufactured December 18, 2014, to July 15, 2015. In the affected vehicles, the fuse block assembly for the heating, ventilation and air conditioning motors in the battery compartment may have been assembled incorrectly.
15V580000 · 145 units · Motor Coach Industries
- May 12, 2015Fire risk2011–2012 MCI D4000, 2014–2015 MCI D4500 — Engine and Engine Cooling
Motor Coach Industries (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured November 12, 2011, to July 11, 2012, and 2014-2015 D4500 motorcoaches manufactured July 4, 2014, to April 30, 2015. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.
15V276000 · 243 units · Motor Coach Industries
- Jun 16, 2014Fire risk2009–2011 MCI D4000, 2009–2011 MCI D4500, 2010 MCI D4505 — Interior Lighting
Motor Coach Industries, Inc (MCI) is recalling certain model year 2009-2011 D4000 and D4500 and 2010 D4505 motor coaches equipped with LED lights interior lights powered by either a Vansco or IO multiplex system. Due to the excessive power draw of the LED lights, heat may build up at the fuse block and connector, causing the components to melt.
14V329000 · 312 units · Motor Coach Industries
- Jun 9, 2014Crash risk2014 MCI D4000, 2014 MCI D4000ISTV, 2014 MCI D4005 and 3 other models — Exterior Lighting
Motor Coach Industries, Inc. (MCI) is recalling certain model year 2014 D4000, D4005, D4000ISTV, D4500, D4505, and J4500 motor coaches manufactured July 2013 to April 2014. The multiplex electrical systems controller may unintentionally turn off the vehicle's headlights while the vehicle is in gear.
14V370000 · 686 units · Motor Coach Industries
- Feb 28, 2014Fire risk2011–2012 MCI D4000 — Engine and Engine Cooling
Motor Coach Industries, Inc. (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured March 2011 through July 2012 and equipped with certain Cummins Westport model ISL G. Condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold pressure sensor.
14V085000 · 96 units · Motor Coach Industries
- Oct 17, 2013Fire risk2000–2001 MCI 102D3, 2000–2001 MCI 102DL3, 2000–2001 MCI 102EL3 and 10 other models — Electrical System
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 conducting electricity after being exposed to heat.
13V498000 · 10K units · Motor Coach Industries
- Apr 16, 2013Fire risk2012–2013 MCI D4000, 2012–2013 MCI D4000ISTV, 2012–2013 MCI D4005 and 2 other models — Engine and Engine Cooling
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 the pipe during operation.
13V142000 · 155 units · Motor Coach Industries
- May 31, 2012Fire risk2009–2011 MCI D4000, 2009–2011 MCI D4500, 2010 MCI D4505 — Interior Lighting
MOTOR COACH INDUSTRIES, INC (MCI) IS RECALLING CERTAIN MODEL YEAR 2009-2011 D4000, D4500 AND 2010 D4505 MOTOR COACHES EQUIPPED WITH LED LIGHTS INTERIOR LIGHTS AND POWERED BY EITHER A VANSCO OR IO MULTIPLEX SYSTEM. DUE TO EXCESSIVE POWER DRAW OF THE LED LIGHTS, HEAT MAY BUILD UP AT THE FUSE BLOCK AND CONNECTOR, CAUSING COMPONENTS TO MELT.
12V250000 · 312 units · MOTOR COACH INDUSTRIES, INC
- Oct 26, 2011Crash risk2007–2012 MCI D4000, 2007–2012 MCI D4000ISTV, 2007–2012 MCI D4005 and 4 other models — Electronic Stability Control (esc)
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 BODY ROLL AND ROAD INCLINATION CHARACTERISTICS MAY ADVERSELY AFFECT THE SLIP ANGLE CALCULATION OF THE ELECTRONIC STABILITY CONTROL (ESC) SYSTEM. THIS MIGHT CAUSE THE ESC TO PERCEIVE AN OVER STEERING SITUATION AND THEREFORE APPLY THE OUTER WHEEL BRAKE ON THE FRONT AXLE UNTIL THE VEHICLE IS PERCEIVED TO BE STABLE.
11V524000 · 2K units · MOTOR COACH INDUSTRIES, INC
- Jan 12, 2011Crash risk2010–2011 MCI D4000, 2010–2011 MCI D4500, 2010–2011 MCI D4505 — Engine and Engine Cooling
MCI IS RECALLING CERTAIN MODEL YEAR 2010-2011 D4500, D4505, AND D4000 MOTOR COACHES. THE AFFECTED PULLEY COVERS MAY LACK CERTAIN WELDS REQUIRED TO KEEP THE COVERS ATTACHED TO THE COACH STRUCTURE.
11V016000 · 138 units · MOTOR COACH INDUSTRIES, INC
- May 11, 2010Crash risk2010 MCI D4000, 2010 MCI D4005, 2010 MCI D4500 and 3 other models — Power Train
MCI IS RECALLING CERTAIN MODEL YEAR 2010 D4000, D4005, D4500, D4505, E4500, AND J4500 MODEL MOTOR COACHES MANUFACTURED FROM SEPTEMBER 2009 THROUGH MAY 2010, EQUIPPED WITH ARVINMERITOR FRONT AND TAG AXLE ASSEMBLIES. THE SUSPECT AXLES MAY HAVE HAD IMPROPER TORQUE APPLIED TO THE HUB/ROTOR/WHEEL ADAPTER BOLTS DURING THE ASSEMBLY PROCESS. REDUCED BOLT TORQUE COULD LEAD TO VIBRATION LOOSENING OF THE BOLT.
10V199000 · 335 units · MOTOR COACH INDUSTRIES, INC
- Mar 24, 2010Crash risk2009 MCI D4000, 2008–2010 MCI D4500, 2008–2010 MCI D4505 — Equipment Adaptive/mobility
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 POSSIBLE FOR THE OPERATOR TO INSERT THE BELT TONGUE INTO THE BUCKLE WITHOUT FULLY ENGAGING THE LATCHING MECHANISM. IN THIS CASE, THE RESTRAINT BELT WOULD APPEAR TO BE LATCHED, AND THE OPERATOR COULD RUN THE LIFT. IF THE RESTRAINT BELT TONGUE IS NOT FULLY ENGAGED INTO THE RESTRAINT BELT BUCKLE, AND LATCHED, THE LIFT MAY OPERATE WITH AN OCCUPANT ON THE PLATFORM.
10V114000 · 249 units · MOTOR COACH INDUSTRIES, INC
- Mar 9, 2010Crash risk2000–2009 MCI D4000, 2000–2010 MCI D4500, 2005–2007 MCI D4505 — Equipment Adaptive/mobility
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 THROUGH THE CASSETTE DOOR AND EXTENDING BEYOND THE OUTSIDE OF THE DOOR WHEN THE COACH IS IN MOTION, PARTICULARLY WHEN THE COACH IS MAKING A LEFT TURN.
10V087000 · 4K units · MOTOR COACH INDUSTRIES, INC
- Nov 18, 2009Fire risk2005–2008 MCI D4000, 2005–2009 MCI D4500, 2005–2009 MCI D4505 — Electrical System
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.
09V446000 · 1K units · MOTOR COACH INDUSTRIES, INC
- Nov 3, 2009Fire risk2003–2007 MCI D4000, 2002–2009 MCI D4500, 2007 MCI D4505 — Interior Lighting
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.
09V432000 · 701 units · MOTOR COACH INDUSTRIES, INC
- Dec 19, 2006Safety1997–2006 MCI 102D3, 1997–2006 MCI 102DL3, 1997–2006 MCI 102DL3SS and 2 other models — Electrical System
ON CERTAIN MOTOR COACHES, THE BOOST CONNECTOR HOUSING CAN FAIL OVER TIME, EXPOSING THE POSITIVE AND NEGATIVE TERMINALS.
06V481000 · 2K units · MOTOR COACH INDUSTRIES, INC
- Jul 6, 2006Fire risk2001–2005 MCI 102EL3, 2003–2006 MCI D, 2003–2006 MCI D4000 and 4 other models — Visibility
ON CERTAIN MOTOR COACHES EQUIPPED WITH A SLIDE SWITCH TO CONTROL THE DEFROSTER BLOWER SPEED, THERE IS A SPEED CONTROLLER FOR EACH OF THE TWO DEFROSTER FAN MOTORS. THE SPEED CONTROLLER MAY FAIL CAUSING THE FAN MOTOR TO OPERATE CONTINUOUSLY IN THE "HIGH" SPEED MODE, AND THE CARRIER SLIDE SWITCH MAY FAIL TO REDUCE OR OTHERWISE CONTROL THE FAN MOTOR SPEED.
06V241000 · 2K units · MOTOR COACH INDUSTRIES, INC
- Apr 27, 2006Fire risk2000–2005 MCI 102EL3, 2000–2006 MCI D, 2000–2006 MCI D4000 and 8 other models — Engine and Engine Cooling
ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.
06V140000 · 5K units · MOTOR COACH INDUSTRIES, INC
- Apr 4, 2002Safety2002 MCI D4000, 2002 MCI D4500 — Electrical System
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.
02V103000 · 300 units · MOTOR COACH IND., INC.