NHTSA vehicle safety data

2006 MCI D4000 Recalls, Ratings & Complaints

The 2006 MCI D4000 has 9 NHTSA recall campaigns and 0 owner complaints on file as of October 16, 2026. Recall repairs are usually free at an authorized MCI dealer.

NHTSA recall and complaint data for the 2006 MCI D4000. Recall data is refreshed daily from NHTSA.

STRUCTURE:BODY:DOOR

NHTSA #25V853000

Reported December 10, 2025 · Motor Coach Industries, Inc

Potentially affected: 15,454 vehicles

Defect description

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."

Safety consequence

The incorrect window glazing material may reduce the driver's visibility, increasing the risk of a crash.

Manufacturer 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

NHTSA #13V498000

Reported October 17, 2013 · Motor Coach Industries

Potentially affected: 10,016 vehicles

Defect description

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.

Safety consequence

Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

Manufacturer 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.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

EQUIPMENT ADAPTIVE/MOBILITY

NHTSA #10V087000

Reported March 9, 2010 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 4,457 vehicles

Defect description

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.

Safety consequence

IF THE COACH IS IN MOTION, POTENTIAL INJURY TO PERSONS AND/OR DAMAGE TO OTHER VEHICLES OR PROPERTY COULD OCCUR.

Manufacturer 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.

Notes

MCI RECALL NO. 341.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

NHTSA #09V446000

Reported November 18, 2009 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 1,007 vehicles

Defect description

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.

Safety consequence

THIS COULD RESULT IN A FIRE.

Manufacturer 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.

Notes

OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

INTERIOR LIGHTING

NHTSA #09V432000

Reported November 3, 2009 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 701 vehicles

Defect description

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.

Safety consequence

A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.

Manufacturer 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.

Notes

MCI RECALL NO. 335.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

VISIBILITY:GLASS, SIDE/REAR

NHTSA #07E042000

Reported June 22, 2007 · DURA AUTOMOTIVE SYSTEMS, INC.

Potentially affected: 4,284 vehicles

Defect description

CERTAIN DURA SIDE BODY EGRESS WINDOWS, SIDE BODY LAVATORY EGRESS WINDOWS, AND NON-EGRESS SIDE BODY WINDOWS MANUFACTURED BETWEEN NOVEMBER 1, 2005, AND JULY 19, 2006, INSTALLED AS ORIGINAL EQUIPMENT ON CERTAIN MY 2006 AND 2007 MOTOR COACH INDUSTRIES (MCI) D COACHES. THE WINDOWS WERE PRODUCED WITH INCONSISTENT PRIMING ON THE PRIMARY AND SECONDARY BOND LINES WHICH FAILS TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 217, BUS EMERGENCY EXITS AND WINDOW RETENTION AND RELEASE.

Safety consequence

THE PURPOSE OF THIS STANDARD IS TO MINIMIZE THE LIKELIHOOD OF OCCUPANTS BEING THROWN FROM THE BUS AND TO PROVIDE A MEANS OF READILY ACCESSIBLE EMERGENCY EGRESS.

Manufacturer remedy

MCI WILL NOTIFY OWNERS INSTRUCTING THEM TO INSPECT THE WINDOWS FOR SIGNS OF WATER LEAK, WIND NOISE, OR VISABLE PARTIAL DE-BONDING. WINDOWS SHOWING THESE SIGNS WILL BE REPLACED FREE OF CHARGE BY DURA. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2007. OWNERS CAN CONTACT DURA AT 248-844-1615.

Notes

CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

ELECTRICAL SYSTEM:12V/24V/48V BATTERY

NHTSA #06V481000

Reported December 19, 2006 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 1,617 vehicles

Defect description

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

Safety consequence

THIS COULD RESULT IN THE GROUNDING OF AN UNPROTECTED CIRCUIT AND COULD LEAD TO A THERMAL EVENT IF NOT CORRECTED.

Manufacturer 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.

Notes

MCI RECALL NO. 274.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM

NHTSA #06V241000

Reported July 6, 2006 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 1,768 vehicles

Defect description

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.

Safety consequence

THE SPEED CONTROLLER MAY OVERHEAT AND RESULT IN A THERMAL EVEN, SUCH AS SMOKING OR POSSIBLE FIRE.

Manufacturer remedy

DEALERS WILL REPLACE THE DEFROSTER SPEED CONTROLLER FREE OF CHARGE. THE RECALL BEGAN ON JULY 20, 2006. OWNERS MAY CONTACT MOTOR COACH AT 1-800-241-2947.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

NHTSA #06V140000

Reported April 27, 2006 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 4,765 vehicles

Defect description

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

Safety consequence

A FIRE CAN RESULT SHOULD THE TURBOCHARGER FAIL.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Other MCI D4000 model years

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