2011 MCI D4505 recalls

• Visual System#2026007January 15, 2026

  2,161 units affected

  Issue: On certain buses, the wrong glass may have been installed on the lower front entry door panel. As a result, the glass may not meet certain requirements of Canadian regulations. Safety Risk: An incorrect window glass could reduce visibility and increase the risk of a crash. Corrective Action: Motor Coach Industries (MCI) will notify owners by mail and provide you with instructions for how to replace the lower glass panel. Alternatively, you may schedule an appointment to have the lower glass panel replaced at an authorized MCI service center.

• Engine#2018256May 14, 2018

  138 units affected

  On certain motor coaches, the exhaust bellows pipe may fail prematurely and cause a leak. An exhaust leak during a regeneration event could allow the leakage of hot gases and could increase the risk of fire, causing property damage and/or personal injury. Correction: Dealers will install a new exhaust pipe assembly.

• Engine#2017280May 25, 2017

  35 units affected

  On certain vehicles, the bellows pipe (a component of the exhaust system) may have been installed incorrectly and could fail. As a result, combustion from a Diesel Particulate Filter regeneration event could exit the failed bellows pipe instead of being completely contained within the exhaust system. If this occurs, the hot combustion gases could cause a fire which may result in property damage and/or personal injury. Correction: Authorized MCI service facilities will inspect and, if necessary, replace the bellows pipe. Note: This is an expansion of recall 2013-121.

• Electrical#2014236June 19, 2014

  85 units affected

  Certain coaches previously repaired as part of recall 2012173 may require additional modifications. The power draw from the LED interior lights may exceed the design limits of the fuse block terminal and power splice connector installed as part of the previous recall. As a result, these components could overheat, potentially resulting in a vehicle fire causing property damage and/or personal injury. Correction: MCI authorized facilities will install a revised fuse holder for the LED interior lights.

• Electrical#2012173May 30, 2012

  85 units affected

  On certain coaches, the power draw from the LED interior lights may exceed the design limits of the electrical circuit. This could allow certain components to overheat, which could result in a vehicle fire causing property damage and/or personal injury. Correction: MCI authorized facilities will modify the electrical circuit for the LED interior lights.

• Other#2011377October 21, 2011

  245 units affected

  On certain vehicles, specific operating conditions (such as tight, successive, highly banked curves in opposite directions), could trigger unintended Electronic Stability Control (ESC) system intervention. As a result, the ESC may unnecessarily apply one of the front brakes in order to correct the perceived oversteer condition. This may cause the vehicle to deviate from the intended path, thereby increasing the risk of a crash causing property damage and/or personal injury. Correction: Dealers will replace the ESC module.

Canadian data updated August 24, 2026

• STRUCTURE:BODY:DOOR#25V853000December 10, 2025

  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."

  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.

• ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE#18V309000May 13, 2018

  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: 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.

• ENGINE AND ENGINE COOLING:EXHAUST SYSTEM#17V337000May 24, 2017

  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: 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.

• SEATS#16V020000January 20, 2016

  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.

  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.

• ELECTRICAL SYSTEM#13V498000October 17, 2013

  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.

  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.

• ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR#11V548000November 10, 2011

  MOTOR COACH INDUSTRIES (MCI) IS RECALLING CERTAIN MODEL YEAR 2010-2011 D4505 MOTOR COACHES MANUFACTURED FROM MAY 1, 2010, THROUGH SEPTEMBER 30, 2011. THESE VEHICLES WERE EQUIPPED WITH PENNTEX ALTERNATORS THAT, AS INSTALLED, MAY COLLECT MOISTURE AT THE POWER STUD. THIS MOISTURE MAY RESULT IN CORROSION BUILDUP AT AND AROUND THE POWER STUD BASE.

  Risk: THIS CORROSION MAY CREATE A SHORT CIRCUIT BETWEEN THE POWER STUD AND THE ALTERNATOR BODY, WHICH IN TURN COULD RESULT IN BURNING OF THE POWER STUD OR THE POWER CABLE END. THIS COULD INCREASE THE RISK OF A FIRE. ADDITIONALLY, THE VEHICLE BATTERY COULD DISCHARGE WHICH COULD CAUSE THE VEHICLE TO STALL.

  Remedy: MCI WILL INSPECT AND MODIFY THE ALTERNATOR INSTALLATION FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 30, 2011. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.

• ELECTRONIC STABILITY CONTROL (ESC)#11V524000October 26, 2011

  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.

  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.

• ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN#11V016000January 12, 2011

  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.

  Risk: THE COVER WILL EVENTUALLY FAIL AS A RESULT OF FATIGUE, AND THE COVER MAY BECOME DETACHED FROM THE COACH AND FALL AND STRIKE A PERSON OR OBJECT, RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.

  Remedy: MCI WILL INSPECT AND REPLACE AS NECESSARY THE IDLER PULLEY COVERS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON FEBRUARY 10, 2011. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.