Mci J4500 2020

Complaint Information: Recalls, Investigations, Service Bulletins, Recall Investigations, OBD II Codes

NHTSA Mandated Recalls

  • Recall 249104 [USA]: Obstructed rear lighting may reduce the visibility of the vehicle to other drivers, increasing the risk of a crash.
    Motor coach industries (mci) is recalling certain 2019-2021 d45crtle, j3500, and j4500 coaches, equipped with a rear-mounted bike rack. The vehicle's rear lighting may be obstructed when bikes are installed on the bike rack. As such, these vehicles fail to comply with the requirements of federal motor vehicle safety standard number 108, "lamps, reflective devices, and associated equipment."
    mci will provide instructions and a kit to add lighting to the rear-mounted bike rack, free of charge. Owner notification letters were mailed august 31, 2023. Owners may contact mci customer service at 1-800-241-2947.
    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.Nhtsa.Gov.

  • Recall 180725 [USA]: A high pressure fuel leak in the presence of an ignition source can increase the risk of a fire.
    Motor coach industries (mci) is recalling certain 2019-2022 d4000 istv, d4500, 2021 d4000, d4520, 2020-2021 d4505, d4005, 2020-2022 d45crtle, and 2019-2021 j4500 vehicles equipped with certain cummins x12 diesel engines. The fuel tubes between the fuel rail and the injectors for cylinders four, five, and six may fatigue and crack, which can result in a high pressure fuel leak.
    on engines with 75 miles or less, cummins dealers will install vibration isolators to the fuel tubes. Engines with more than 75 miles will receive new fuel tubes with vibration isolators. Repairs will be performed free of charge. Owner notification letters were mailed march 11, 2022. Owners may contact mci customer service at 1-800-241-2947. Mci's number for this recall is r21-028.
    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.Nhtsa.Gov.

  • Recall 212923 [USA]: Mdp circuit board failure can result in a fire or an unexpected vehicle shutdown, increasing the risk of a crash.
    Motor coach industries (mci) is recalling certain 2018 d4000, 2018-2020 d4005, d4000istv, 2017-2020 d4500, d4505, 2018-2021 j3500, 2017-2021 j4500, 2020 d4520, and 2018-2021 d45crtle motorcoaches. The main distribution panel (mdp) located within the battery compartment contains a circuit board that may fail.
    mci service centers will remove the mdp and install a new main disconnect and circuit breaker panel, free of charge. Owner notification letters were mailed november 12, 2021. Owners may contact mci's customer service at 1-800-241-2947. Mci's number for this recall is r21-010.
    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.Nhtsa.Gov.

  • Recall 206547 [USA]: A fuel leak in the presence of an ignition source increases the risk of a fire.
    Motor coach industries (mci) is recalling certain 2017-2018 d4000, 2017-2019 d4005, d4000istv, d4505, 2017-2020 d4500, j4500, 2018-2020 d45crtle, and 2018-2021 j3500 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.
    dealers will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on june 28, 2021. Owners may contact mci customer service at 1-800-241-2947. Mci's number for this recall is r21-009.
    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.

  • Recall 214323 [USA]: The power cables may chafe, increasing the risk of a fire.
    Motor coach industries (mci) is recalling certain 2018-2021 j4500 and 2018-2020 d45crtle vehicles. The power cables may have been improperly installed and routed in the vehicle battery compartment, which may result in chafing.
    mci will notify owners, and dealers will inspect and if necessary, correct the clearance for the power cables in the battery compartment, free of charge. The recall began march 12, 2021. Owners may contact mci customer service at 1-800-241-2947. Mci's number for this recall is r21-003.
    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.

  • Recall 143598 [USA]: The spilled coolant may increase the risk of a crash. additionally, transferring passengers from the disabled bus can increase their risk of injury.
    Motor coach industries (mci) is recalling certain 2017-2020 j4500 motor coaches. The coolant hose may fail, resulting in a low coolant warning followed by an engine shut down sequence, as well as the potential for engine coolant spilling on the roadway.
    mci will notify owners, and dealers will replace the coolant hose, free of charge. The recall began october 30, 2020. Owners may contact mci customer service at 1-800-241-2947. Mci's number for this recall is sb 486.
    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.

  • Recall 147009 [USA]: If the engine shuts down or loses power while the vehicle is in motion, this may increase the risk of a crash.
    Motor coach industries (mci) is recalling certain 2018-2020 d4000, d4005, d4500, d4505 and d45crtle buses manufactured with electric cooling fans (e-fan) for the radiator and charge air cooler, borg warner 55si model dual alternator configuration (with a sense stud and wire), and parker vansco multiplexing module (vmm) multiplex system. A build-up of debris, corrosion, and/or water flow could cause a high resistance path to ground for the sense stud on the back of the alternator and cause the alternator to produce excessive voltage output, which may exceed the threshold limit currently programmed in the vmm and result in a loss of engine power and vehicle shutdown.
    mci will notify the affected owners, and dealers will install a new application code in the parker vmm multiplex modules increasing the overvoltage threshold limit, free of charge. The recall began july 23, 2020. Owners may contact mci customer service at 1-800-241-2947. Mci's number for this recall is sb 479.
    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.

  • Recall 153625 [USA]: Inability to use the seat belt may increase the risk of injury in the event of a crash.
    Motor coach industries (mci) is recalling certain 2015-2016 d4000, 2015-2020 d4500 and d4505, 2016-2020 j4500, 2018 j3500, and 2017 d4005 buses. The seat belts may not extend from the retracted position, rendering the seat belt unusable. As such, these vehicles fail to comply with the requirements of federal motor vehicle safety standards (fmvss) number 208, "occupant crash protection," and number 209, "seat belt assemblies."
    mci will notify the affected owners, and dealers will inspect and replace the seat belts, as necessary, free of charge. Mci issued owners an interim notification june 26, 2020. The recall began january 13, 2021. Owners may contact mci customer service at 1-800-241-2947. Mci's number for this recall is sb 482.
    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.

  • Recall 2021761 [Canada]: Fuel supply
    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.

  • Recall 2021595 [Canada]: Electrical
    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.

  • Recall 2021058 [Canada]: Electrical
    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.

  • Recall 2020276 [Canada]: Electrical
    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.

To ensure accuracy and for your safety, it is recommended to do a free VIN recall check here or here [USA] - UK - Canada.

Bulletins

Bulletins are notices put out by manufacturers in conjunction with the NHTSA to notify the public of manufacturing issues or changes.

  • No comms 2024-04 - UNKNOWN OR OTHER: There are no manufacturer communications in accordance with 49 cfr 579.5 to report for april 2024 for motor coach industries.
  • ITS60877 - ELECTRICAL SYSTEM: Instruction to service its60877 provides instructions to relocate an impact sensor in baggage bay to reduce nuisance activations.
  • TSIB 22-04 - STRUCTURE: Instructions to improve sealing in the front junction box.
  • TSIB 22-12 - ELECTRICAL SYSTEM: Mci has released technical service information bulletin (tsib) 22-12 to address concerns with water ingress in remote switch box. The tsib provides guidance on how to rework the box to inhibit water intrusion and connector corrosion
  • TSIB 22-04 - STRUCTURE: Technical service information bulletin describing the retrofit for the front junction box cover on specifically equipped buses.
  • ITS60421 - ELECTRICAL SYSTEM: This technical instruction is a description of the inspections and cleaning procedures being recommended by mci due to the parts shortages which are impacting the repair inspections associated with nhtsa recall 21v-748. These are the same i
  • TSIB 22-02 - ENGINE AND ENGINE COOLING: This technical service information bulletin is a supplemental reminder to all mci owners/operators of vehicles which are affected by the cummins equipment recall 21e-099 and mci vehicle recall 21v-971.
  • ITS60421 - ELECTRICAL SYSTEM: This instruction to service (its) is a description of the inspections being recommedned by mci due to the parts shortages which are impacting the repair instructions associated with nhtsa recall 21v-748. These are the same instructions as o
  • TSIB 22-01 - EQUIPMENT: This is an upgrade to technical service information bulletin tsib 21-10 issued in january of 2022 which is specific to buses operating in severe duty and or corrosive environments. These bulletins have been issued to recommend interim inspe
  • TSIB 21-10 - ELECTRICAL SYSTEM: This technical service information bulletin describes interim inspection procedures required every 6000 miles on specific motor coaches due to the global parts shortage and subsequent delay in available parts to conduct the corrective actio
  • TSIB 21-08 - SEATS: Technical service information bulletin describing an update to the preventaive maintenance requirements for specifically equipped motor coaches with kiel avane model passenger seats.
  • TSIB 21-05 - ENGINE AND ENGINE COOLING: This technical sevice information bulletion is to advise of a part number supersession of the coolant hump hose, mci pn 6l-8-353, to mci pn 06-08-2262.
  • FCP 493 - FUEL SYSTEM, DIESEL: Technical instruction describing how to replace the plastic fuel tank filler neck gasket.
  • SB 3146 - EQUIPMENT: This service bulletin outlines the steps to add the secondary air filter. The secondary filter can only be used with primary air filter, mci p/n: 09-03-1858.
  • SB 3145 - EQUIPMENT: This service bulletin informs affected owners of the steps to remove the unused saucon provisional connector, mci p/n 19-11-2941, located in the front junction box on coaches without a saucon telematics module.
  • SB 3139 - EQUIPMENT: This service bulletin provides a checklist of actions to perform on a daily, weekly and monthly basis for parked coaches before they are considered ready for driving.
  • SB 485 - EQUIPMENT:APPLIANCE:AIR CONDITIONER: This service bulletin informs affected owners that the a/c compressor on certain j4500 coaches are making excessive noise and vibration which may result in vibration transferred to the coach frame, possibly resulting in noise and passenger
  • SB 484 - ELECTRICAL SYSTEM: This service bulletin informs affected owners that on certain d45crtle and j4500 model coaches equipped with cummins x12 engines, the top alternator power and ground cables may potentially come in contact with the edge of the clamp mounting
  • FCP 483 - EQUIPMENT: This service bulletin advises owners of affected vehicles that mobile climate control ("mcc") has notified mci that certain new style evaporator motors supplied by mcc may have inadequate electrical contacts at the main circuit board, which
  • FCP 480 - EQUIPMENT ADAPTIVE/MOBILITY: This service bulletin advises owners of affected vehicles that modine manufacturing co. Has notified mci that some of the e-fan engine cooling modules may have their harness rubbing on an uncovered metal edge, which could lead to harness da
  • SB 3132 - EQUIPMENT: This service bulletin outlines the steps to relocate the ambient temperature sensor from the spare tire compartment to the bumperette to improve the accuracy of the sensor reading. This service bulletin needs to be done in conjunction with
  • SB 3131 - SUSPENSION: This service bulletin outlines the steps to replace the adapter plates on the tag axle bellows to increase support for the bellow piston.
  • FCP 478 - SERVICE BRAKES, AIR: This service bulletin advises owners of affected vehicles that zf has notified mci that some brake chambers installed on the zf drive axle have had water ingress, causing malfunction of the pneumatic brake system and dragging brakes during
  • FCP 475 - VEHICLE SPEED CONTROL: This service bulletin advises owners of affected vehicles that the throttle pedal sensors may provide intermittent, erratic data and cause the "engine check" light to become illuminated, and how repairs can be made to correct the vehicles.
  • D20M4 - ENGINE AND ENGINE COOLING: Ddc field service campaign for ghg17 detroit dd13 engines requiring software reprogramming and new emission label replacement. This field service applies only to mci (motor coach industries) vehicles.
  • P16-42 - ENGINE AND ENGINE COOLING: This procedure outlines the steps to space out the condenser discharge and heater coolant lines.
  • P16-41 - EQUIPMENT: This procedure outlines steps to replace the double groove belt on the a/c compressor with single groove matched belts.
  • FCP 3130 - EQUIPMENT: This service bulletin outlines the steps to install reinforcement bracket for the mudflap on coaches equipped with mci p/n 03-33-2646.
  • FCP 3129 - STEERING: This service bulletin outlines the necessary steps to inspect the power steering system for proper operation. It also lists the necessary steps to replace the power steering seals if needed.
  • P03-276 - VISIBILITY: This procedure outlines steps to add mechanical fasteners to the dual lock tape retaining the rear window trim panel.
  • SB 3128 - ENGINE AND ENGINE COOLING: This service bulletin advises customers facing issues with a low engine oil pan protector profile how to replace it with a new model with higher ground clearance.
  • P12-24 - EQUIPMENT: This procedure outlines the steps to inspect and adjust ground clearance setting.
  • SB 3123 - EQUIPMENT: This service bulletin informs owners of model year 2018-2020 j3500 and j4500 model coaches of the procedure to insulate the gap in the area between the front cap and under the dash panel on the driver's side, that will help shield the ambie
  • SB 3125 - SUSPENSION: This service bulletin informs owners of model year 2018-2020 j4500 model coaches hearing noise near the front sway bar during driving to apply anti-seize lubricant per the instructions.
Known Recall Investigations

  • Supply and return heater hose rupture investigation as of 20200313

    By letter dated august 31, 2020, motor coach industries (mci) notified the office of defects investigation (odi) of a safety defect that may exist in certain model year (my) 2017-2020 j4500 vehicles. An odi review of early warning reporting (ewr) submissions by mci, on my 2017-2019 j4500 buses, identified ruptured heater hoses on multiple motor coaches leading to the vehicles becoming disabled. Odi communications with fleets found that a low coolant level light with an audible warning would provide notice to the bus driver to pull off the roadway before the bus shut down to prevent catastrophic engine damage. According to the fleets interviewed, there is not sufficient time between the warning and the engine shutting down to allow the driver to pull to a safe location. Multiple reports/interviews describe buses requiring passenger transfer to a second bus at roadside. Analysis of data provided by mci in response to an odi information request (ir) letter showed an elevated frequency of heater hose ruptures. The heater hoses may fail, resulting in a low coolant warning followed by an engine shut down sequence, as well as the potential for engine coolant spilling on the roadway. Following discussions with odi about the elevated failure rates on the heater hoses, mci decided to conduct safety recall 20v-526.With recall action 20v-526 taken by mci, this investigation is closed. Further use of agency resources does not appear to be warranted.The closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist on other model or my vehicles outside of the recall scope. The agency reserves the right to take further action if warranted by the circumstances.The odi report cited above can be reviewed at: http://www-odi.Nhtsa.Dot.Gov/owners/searchnhtsaid using the following identification number: 10168841

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