MCI J4500 recalls

• Lights And Instruments#2026217April 30, 2026

  33 units affected

  Issue: On certain buses, a software problem could cause the tail lamps not to turn on when the daytime running lamps (DRLs) are on. As a result, the buses don't meet certain requirements of Canadian regulations. Safety Risk: Driving without tail lamps in low light conditions could make the vehicle less visible and increase the risk of a crash. Corrective Actions: To reduce the safety risk, Motor Coach Industries (MCI) advises you to drive the bus with the headlamps on until the recall repairs are completed. MCI will notify owners by mail and provide you with instructions for how to update the vehicle software. Alternatively, you may schedule an appointment to have the update performed at an authorized MCI service center.

• 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.

• Label#2025367July 8, 2025

  21 units affected

  Issue: On certain buses, the labels for the emergency exit windows may not be in the correct location. This could delay occupants from escaping the bus in an emergency. Safety Risk: Emergency exit labels that aren't in the correct location could create confusion and increase the risk of injury in an emergency. Corrective Actions: Motor Coach Industries will notify owners in writing and provide you with new emergency exit labels and instructions for where to install them. Alternatively, you may schedule an appointment to have the labels installed at an authorized MCI service center.

• Fuel System#2021761December 15, 2021

  75 units affected

  Issue: On certain buses, the fuel tubes between the fuel rail and the injectors may crack and create a fuel leak. Note: This recall only affects buses equipped with a Cummins X12 diesel engine. Safety Risk: A fuel leak can create the risk of a fire. Corrective Actions: Cummins will notify owners by mail and instruct you to take your bus to a Cummins authorized service center to replace the fuel tubes for cylinders 4, 5 and 6 and install vibration isolators.

• Electrical#2021595September 24, 2021

  202 units affected

  Issue: On certain buses, a circuit board for the main distribution panel (MDP) located in the battery compartment may fail. If this happens, the circuit board could overheat and cause a sudden vehicle shutdown. Safety Risk: A circuit board that overheats could create the risk of a fire. A sudden loss of engine power could increase the risk of a crash. Corrective Actions: Motor Coach Industries (MCI) will notify owners by mail instruct you to take your bus to an authorized repair facility to replace the main distribution panel (MDP) with a new part that has a main disconnect and circuit breaker assembly. To reduce the safety risk, MCI recommends that you should inspect the condition of the MDP circuit board every 9600 km (6000 miles) until this recall is completed.

• Fuel System#2021297May 18, 2021

  116 units affected

  Issue: On certain buses, the fuel rail assembly could develop a leak. Note: This recall only affects buses equipped with a Cummins L9 or ISX12 diesel engine. Safety Risk: A fuel leak can create the risk of a fire. Corrective Actions: Motor Coach Industries (MCI) will notify owners by mail and instruct you to take your bus to a Cummins authorized service center to inspect the fuel rail. If damage is found, the fuel rail and fuel lines will be replaced. If no damage is found, the fuel rail will be reassembled with new crush washers using a special tool.

• Electrical#2021058February 11, 2021

  126 units affected

  Issue: On certain motor coaches, the power cable in the battery compartment may have been routed incorrectly. As a result, the cable could be damaged by contact with nearby parts. If this happens, the cable could create a short circuit. Safety Risk: A short circuit could create the risk of a fire. Corrective Actions: Motor Coach Industries (MCI) will notify owners by mail and instruct you to take your vehicle to a dealer to inspect the power cable in the battery compartment and reposition it, if necessary.

• Engine#2020501October 21, 2020

  184 units affected

  Issue: On certain buses, the engine coolant hoses may be defective and could fail. As a result, engine coolant could leak. If this happens, a low coolant warning may appear and the engine can shut down. It could also cause coolant to spill onto the road. Safety Risk: A sudden loss of engine power could increase the risk of a crash. Additionally, an engine coolant leak could create a hazard for other road users. A bus that is disabled could result in a transfer of passengers in an uncontrolled environment, which may create a risk of injury. Corrective Actions: Motor Coach Industries (MCI) will notify owners by mail and advise you to replace the engine coolant hoses. They will supply you with the replacement parts and instructions for completing the repairs.

• Electrical#2020276June 17, 2020

  111 units affected

  Issue: On certain buses, a build-up of corrosion on the alternator connection could cause it to malfunction. If this happens, the alternator voltage output may increase. As a result, the control module may switch off the engine and cause a vehicle shutdown. Safety Risk: A sudden loss of engine power and vehicle shutdown could increase the risk of a crash. Corrective Actions: Motor Coach Industries (MCI) will notify owners by mail and instruct you to take your bus to an authorized repair facility to update the software in the Vehicle Multiplexing Module (VMM). MCI also recommends periodically inspecting, cleaning and re-applying corrosion inhibitor to the alternator.

• Brakes#2020179April 27, 2020

  259 units affected

  Issue: On certain buses, the brake hoses may be routed incorrectly and could become damaged or fail. If this happens, air could leak from the hose and cause a delay in the front brakes activating. This would reduce braking performance. Safety Risk: Reduced brake performance can cause extended stopping distances and increase the risk of a crash. Corrective Actions: Motor Coach Industries (MCI) will notify owners by mail and instruct you to inspect the brake hoses. MCI will supply replacement parts and advise owners to replace any hoses that are leaking or damaged.

• Structure#2019049February 5, 2019

  50 units affected

  Issue: On certain motor coaches, the left-rear side window may not be properly attached. This could cause the window to separate from the vehicle. Safety Risk: If the window separates, it could fall and become a hazard for road users and bystanders. This could create a risk of injury and/or a crash. Corrective Actions: The company will notify owners by mail. Owners can choose to have the necessary parts and instructions sent to them to complete the repair themselves, or they can take their vehicle(s) to a dealer to inspect the window mounting. The window will be repaired or replaced as necessary and retaining clips will be installed. Note: This recall supersedes recall 2018-171. All vehicles require a new inspection and repair under this recall.

• Steering#2019006January 8, 2019

  177 units affected

  Issue: Certain buses built with a rear tag-axle steering system may exhibit a steering lock-up at highway speed. Safety Risk: This problem could cause a sudden loss of steering control that could create the risk of a crash. Corrective Action: A final repair has not yet been determined. The cause of this problem is under investigation. In the interim, the company will notify owners by mail and advise them to immediately verify that the rear tag-axle caster adjustment is within specification.

• Seats And Restraints#2018545October 4, 2018

  3 units affected

  Certain motor coaches equipped with the optional 60 passenger seating arrangement do not conform to the requirements of Canada Motor Vehicle Safety Standard (CMVSS) 217 - Bus Window Retention, Release and Emergency Exits. The motor coaches do not meet the minimum emergency exit requirements of the standard, which could increase the risk of injury in the event of an emergency. Correction: Dealers will install 2 additional emergency exit windows and emergency exit labelling.

• Other#2018171April 9, 2018

  6 units affected

  On certain motor coaches, the rear left hand side window is mounted using adhesive and fasteners that may not have been installed correctly during assembly. Under certain circumstances the rear side window could separate from the vehicle and become a hazard that for other road users, increasing the risk of a crash causing injury and/or damage to property. Correction: Dealers will conduct a push out test of all affected windows and replace the ones that fail. Note: This recall is superseded by recall 2019049. Please see <a href="http://wwwapps.tc.gc.ca/Saf-Sec-Sur/7/VRDB-BDRV/search-recherche/detail.aspx?lang=eng&&rn=2019049">recall 2019049</a> for more information.

• Lights And Instruments#2018170April 9, 2018

  8 units affected

  On certain motor coaches, the rear left hand tail lamp harness branch of the engine compartment wiring harness may chafe against the engine coolant tank. If this occurs, the chaffing could damage the wires and cause a loss of power to the left rear tail lamp light, which could decrease vehicle conspicuity and potentially increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will inspect the wiring harness for damage, repair it as necessary and reroute the harness.

• Suspension#2017584November 28, 2017

  158 units affected

  On certain vehicles, the front sway bar could crack at one of the bushing/clamp locations. This could affect vehicle handling and increase the risk of a crash causing injury and/or damage to property. Correction: Vehicles will be fitted with a new sway bar of an updated design. Note: This recall supersedes recall 2017-175

• Brakes#2017540November 2, 2017

  3 units affected

  On certain vehicles, the instrument panel air gauge connections may have been reversed and may not show the actual air pressure in the primary and secondary air systems. The primary gauge would show secondary system pressure, and the secondary gauge would show primary system pressure. This could be misleading to the driver, potentially increasing the risk of injury and/or damage to property. Correction: Gauge connections will be corrected.

• Brakes#2017291June 2, 2017

  147 units affected

  Certain vehicles may not comply with the requirements of Canada Motor Vehicle Safety Standard (CMVSS) 121 - Air Brake Systems. Clamps securing the front brake hoses may have been over-tightened at time of assembly. This could distort the brake hoses, potentially causing damage and leaks. If a leak occurs, it would cause delay brake actuation, and could cause the vehicle to fail to conform to the standard. A delay in brake actuation would increase stopping distances, which could increase the risk of a crash causing injury and/or damage to property. Correction: Dealers will inspect and repair air hoses and clamps as necessary.

• Suspension#2017175March 27, 2017

  61 units affected

  On certain vehicles, the front sway bar could crack at one of the bushing/clamp locations. This could affect vehicle handling and increase the risk of a crash causing injury and/or damage to property. Correction: Vehicles will be fitted with a sway bar of an updated design.

• Brakes#2016479September 29, 2016

  8 units affected

  Certain vehicles may not comply with the requirements of Canada Motor Vehicle Safety Standard 121 - Air Brake Systems. Due to an error in programming, the low air pressure audible and visual warnings may not occur during a low pressure event, contrary to the requirements of the Standard. In the event of a loss of air pressure in the rear air tank (primary) system, the audible and visual warnings notifying the operator of a condition that could result in reduced service brake performance, or unexpected application of the parking brakes, may not occur. Continued operation of the vehicle with a low primary air system condition could increase the risk of a crash causing injury and/or damage to property. Correction: The manufacturer's field service organization will reprogram affected vehicles. Note: The dashboard mounted air pressure gauge does display the correct system air pressure.

• Seats And Restraints#2016026January 20, 2016

  1 units affected

  Certain buses equipped with a Recaro ERGO-M driver seats may be missing welds on the seat structure. As a result, the seatbelt anchorage assembly could separate from the seat structure in the event of a crash, which would increase the risk of injury. Correction: Dealers will inspect for missing welds and if required replace the J-brackets.

• Visual System#2012111March 29, 2012

  77 units affected

  On certain coaches, the transom windows (the rear-most side glass panels) may have been inadequately bonded during the vehicle assembly process and, as a result, could detach from the vehicle. A window separating from the vehicle could strike another vehicle, a stationary object, or a bystander, causing property damage and/or personal injury. Correction: Authorized service facilities will install mechanical retention clips to the transom windows.

• 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.

• Visual System#2011275July 27, 2011

  45 units affected

  On certain coaches, an incorrect fuse (15 amp) may have been installed, during vehicle assembly, in the inline fuse holder for the windshield wiper motor. This could allow the wiper motor fuse to open under a heavy load created by other accessories connected to the electrical stud block. Loss of windshield wiping capability, should it occur during a rainy/snowy day, may compromise the driver's ability to see the road and its users, which could result in a crash causing property damage and/or personal injury. Correction: Dealers will replace the 15 amp fuse with a 30 amp fuse.

• Electrical#2011094March 1, 2011

  9 units affected

  On certain coaches, the wiper motor may have been incorrectly installed during vehicle assembly. The wiper motor may have been connected to a circuit protected by a 7.5A fuse instead of one with a 30A fuse. Under a heavy load such as high winds, heavy rain, snow, or a dry windshield, the wipers may fail. Loss of windshield wiping capability, should it occur during a rainy/snowy day, may compromise the driver's ability to see the road and its users, which could result in a crash causing property damage and/or personal injury. Correction: Dealers will inspect and, if necessary, rework the incorrectly installed wiring.

• Accessories#2011091February 28, 2011

  7 units affected

  On certain coaches, the electrical wires and hydraulic lines which service the wheelchair lift may not have been routed correctly during vehicle assembly and, as a result, could become pinched during lift operation. Should this occur the lift could stop functioning and, should the wires short to ground, it could result in a vehicle fire causing property damage and/or personal injury. Correction: Dealers will inspect the electrical wires and hydraulic lines, replacing them as necessary. Additional clamps will be installed to secure individual wires and lines away from moving parts of the wheelchair lift assembly.

• Wheels#2010153May 11, 2010

  22 units affected

  On certain coaches, the front and/or tag axle assemblies may have been installed with improper torque applied to the hub/rotor/wheel adapter bolts. Reduced bolt torque could lead to vibration loosening of the bolt, and could result in a wheel off condition. This could result in a crash causing property damage, personal injury or death. Correction: Dealers will verify the torque of the affected hub/rotor/wheel adapter plate bolts and replace the bolts as necessary.

• Electrical#2010097March 30, 2010

  209 units affected

  Certain vehicles were equipped with a DOGA brand windshield wiper motor that may fail to operate properly while the wiper system is functioning. The windshield wipers may operate intermittently, operate at a single speed, or stop completely. A faulty windshield wiper motor may reduce the driver's visibility and increases the risk of a crash causing property damage, personal injury or death. Correction: Dealers will replace the wiper motor assembly.

Canadian data updated August 24, 2026