NHTSA vehicle safety data
2004 MCI D4500 Recalls & Complaints
The 2004 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 2004 MCI D4500. Recall data is refreshed daily from NHTSA.
2004 MCI D4500 owner complaints
Owners have filed 1 complaint with NHTSA about the 2004 MCI D4500, describing incidents dated February 13, 2007.
Most-cited components
- Steering 1 complaint
The complaint on file reports a crash (owner-reported, not verified by NHTSA).
Newest complaints
ODI #10183086 · Filed
TL*- THE CONTACTLOST CONTROL OF A 2004 MCI F3500 COACH AT A SPEED OF 30 MPH. THE FAILURE AND CURRENT MILEAGE WERE BOTH 250000. THE CONTACT HAD THE VEHICLE TOWED TO A FACILITY IN ST. LOUIS, WHERE HE WAS TOLD UPON ARRIVAL THAT THE STEERING PIVOT POINT RIPPED FROM THE FRAME OF THE VEHICLE, AND WAS…
NHTSA defect investigations
NHTSA's investigations file lists the 2004 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.
- Engineering Analysis EA12-007: MCI Drive Shaft Safety Loop Failures
Closed December 3, 2015
- Preliminary Evaluation PE12-007: MCI Driveshaft Safety Loop Failures
Closed September 20, 2012
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.
DEFROSTER SPEED CONTROLLERS/CARRIER
NHTSA #06V241000 · Visibility — Defroster/Defogger/HVAC System · NHTSA notice
Reported July 6, 2006 · MOTOR COACH INDUSTRIES, INC
Potentially affected: 1,768 vehicles
Owners notified July 20, 2006 · Vehicles built July 15, 2002 – June 1, 2006 (per NHTSA)
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.
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.
Other MCI D4500 model years
Check your 2004 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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