2007 MCI D4000 recalls

Visibility › Glass, side/rear

Summary

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."

Consequence

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

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.

Components

Visibility › Glass, side/rear; Structure › Body › Door

This recall on nhtsa.gov

Electrical system

Summary

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.

Consequence

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

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.

This recall on nhtsa.gov

Electronic stability control (ESC)

Summary

Motor coach industries (mci) is recalling certain model year 2003, and 2007-2012 e and j models along with model year 2007-2012 D4000, D4005, D4500, D4505, D4000ISTV motor coaches equipped with meritor wabco electronic stability control (ESC) modules, manufactured from October 2002, through October 2011. Under certain road and driving conditions, vehicle body roll and road inclination characteristics may adversely affect the slip angle calculation of the electronic stability control (ESC) system. This might cause the ESC to perceive an over steering situation and therefore apply the outer wheel brake on the front axle until the vehicle is perceived to be stable.

Consequence

If the driver is slow to react during this ESC intervention, the vehicle may deviate from the intended line of travel, increasing the risk of a crash.

Remedy

Mci will notify owners and replace the control module free of charge. The safety recall began on January 4, 2012. Owners may contact mci customer service at 1-800-241-2947.

This recall on nhtsa.gov

Equipment adaptive/mobility

Summary

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.

Consequence

If the coach is in motion, potential injury to persons and/or damage to other vehicles or property could occur.

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.

This recall on nhtsa.gov

Electrical system › Alternator/generator/regulator

Summary

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.

Consequence

This could result in a fire.

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.

This recall on nhtsa.gov

Interior lighting

Summary

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.

Consequence

A short could occur, possibly causing smoke and fire.

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.

This recall on nhtsa.gov

Visibility › Glass, side/rear

• Aftermarket equipment: applies only if this part was installed

Summary

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.

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.

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.

This recall on nhtsa.gov