2004 MCI D4500 recalls and problems
The 2004 MCI D4500 has 7 safety recalls and 1 owner complaint filed with NHTSA. Recall repairs are free at any MCI dealer.
Recalls may cover only some 2004 MCI D4500 vehicles. Check your VIN at NHTSA ↗ to see open recalls for your exact car.
2004 MCI D4500 recalls
Recall 25V-853: Visibility, Structure
Problem: 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."
Risk: The incorrect window glazing material may reduce the driver's visibility, increasing the risk of a crash.
Fix: 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.
Recall 13V-498: Electrical System
Problem: 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.
Risk: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
Fix: 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.
Recall 10V-087: Equipment Adaptive/Mobility
Problem: 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.
Risk: If the coach is in motion, potential injury to persons and/or damage to other vehicles or property could occur.
Fix: 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.
Recall 09V-432: Interior Lighting
Problem: 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.
Risk: A short could occur, possibly causing smoke and fire.
Fix: 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.
Recall 06V-481: Electrical System
Problem: On certain motor coaches, the boost connector housing can fail over time, exposing the positive and negative terminals.
Risk: This could result in the grounding of an unprotected circuit and could lead to a thermal event if not corrected.
Fix: 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.
Recall 06V-241: Visibility
Problem: 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.
Risk: The speed controller may overheat and result in a thermal even, such as smoking or possible fire.
Fix: 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.
Recall 06V-140: Engine and Engine Cooling
Problem: On certain motor coaches equipped with detroit diesel series 60 engines, the turbocharger compressors can fail.
Risk: A fire can result should the turbocharger fail.
Fix: 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.
2004 MCI D4500 problems reported by owners
| Problem area | Reports | |
|---|---|---|
| Steering | 1 |
Most reported parts
- Steering › Linkages › Tie Rod Assembly — 1
Typical mileage at the time of the problem: 250,000 miles (median of owner reports).
Problems that are not covered by a recall are paid repairs; labor rates follow local mechanic pay — see what auto mechanics earn in each state.
Recent 2004 MCI D4500 complaints
Owner reports filed with NHTSA, as written (personal details removed). Complaints are not verified by NHTSA.
Other MCI D4500 years
Frequently asked questions
Does the 2004 MCI D4500 have any recalls?
Yes — NHTSA lists 7 recalls for the 2004 MCI D4500: 25V-853 (visibility, structure), 13V-498 (electrical system), 10V-087 (equipment adaptive/mobility), 09V-432 (interior lighting), 06V-481 (electrical system) and more. Not every vehicle is affected, so check your VIN at nhtsa.gov/recalls.
What is the most common problem with the 2004 MCI D4500?
Owners report steering problems most often (1 reports). The typical mileage when problems were reported is about 250,000 miles.
Are MCI recall repairs free?
Yes. Safety recall repairs are free at authorized MCI dealers, whether you are the first owner or bought the car used.