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NHTSA vehicle safety data

2002 MCI D4500 Recalls & Complaints

The 2002 MCI D4500 has 7 NHTSA recall campaigns and 1 owner complaint on file as of November 3, 2026. Recall repairs are usually free at an authorized MCI dealer.

NHTSA recall and complaint data for the 2002 MCI D4500. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2002 MCI D4500 owner complaints

Owners have filed 1 complaint with NHTSA about the 2002 MCI D4500.

Most-cited components

  • Service Brakes 1 complaint

Newest complaints

  • ODI #10118893 · Filed

    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

Read the full complaint

NHTSA defect investigations

NHTSA's investigations file lists the 2002 MCI D4500 in 2 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Open and recently closed NHTSA defect investigations

Incorrect Front Door Glaze Material/FMVSS 205

NHTSA #25V853000 · Structure — Body — Door · NHTSA notice

Reported December 10, 2025 · Motor Coach Industries, Inc

Potentially affected: 15,454 vehicles

Repair completion: 0.03% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign 22-005 · Owners notified February 4, 2026

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.

Battery Equalizers/DC-DC Converters-Possible Fire

NHTSA #13V498000 · Electrical System · NHTSA notice

Reported October 17, 2013 · Motor Coach Industries

Potentially affected: 10,016 vehicles

Repair completion: 34.55% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Manufacturer campaign 401 · Owners notified February 4, 2014

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.

WHEELCHAIR LIFT

NHTSA #10V087000 · Equipment Adaptive/Mobility · NHTSA notice

Reported March 9, 2010 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 4,457 vehicles

Manufacturer campaign 341 · Owners notified March 31, 2010 · Vehicles built December 1, 2000 – November 30, 2009 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

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> .

HORIZON LED SIDE DESTINATION SIGN/LUMINATOR

NHTSA #09V432000 · Interior Lighting · NHTSA notice

Reported November 3, 2009 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 701 vehicles

Manufacturer campaign 335 · Owners notified November 9, 2009 · Vehicles built January 1, 2002 – June 30, 2009 (per NHTSA)

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> .

BOOST CONNECTOR

NHTSA #06V481000 · Electrical System — 12V/24V/48V Battery · NHTSA notice

Reported December 19, 2006 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 1,617 vehicles

Manufacturer campaign 274 · Owners notified January 2, 2007 · Vehicles built August 26, 1997 – June 7, 2006 (per NHTSA)

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.

TURBOCHARGER FAILURE/POSSIBLE FIRE/SERIES 60/DDC

NHTSA #06V140000 · Engine and Engine Cooling — Engine — Diesel · NHTSA notice

Reported April 27, 2006 · MOTOR COACH INDUSTRIES, INC

Potentially affected: 4,765 vehicles

Vehicles built January 28, 2000 – February 15, 2006 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

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.

MCI/DEFROSTER MOTOR

NHTSA #02V103000 · Electrical System — Wiring · NHTSA notice

Reported April 4, 2002 · MOTOR COACH IND., INC.

Potentially affected: 300 vehicles

Vehicles built November 1, 2001 – March 28, 2002 (per NHTSA)

Defect description

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.

Safety 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.

Manufacturer 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 UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT MCI AT 1-800-241-2947.

Notes

CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

Other MCI D4500 model years

Check your 2002 MCI D4500 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your MCI D4500 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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