2009 Mci D4005 problems, complaints & recalls
Safety recalls (4)
Visibility:glass, Side/Rear 2025-12-10 · campaign 25V853000 · 15,454 vehicles
Defect: 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.
Electrical System 2013-10-17 · campaign 13V498000 · 10,016 vehicles
Defect: 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.
Electronic Stability Control (Esc) 2011-10-26 · campaign 11V524000 · 1,962 vehicles
Defect: 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) SYSTE
Risk: 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.
Fix: 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.
Seats 2010-09-09 · campaign 10V409000 · 105 vehicles
Defect: MCI IS RECALLING CERTAIN MODEL YEAR 2009-2010 D4005 AND D4505 MOTOR COACHES EQUIPPED WITH A NATIONAL SEATING COMPANY DRIVER'S SEAT CONTAINING A STABILUS BLOC-O-LIFT SHOCK. THE DRIVER'S SEAT SHOCK DAMPER MAY BREAK ALLOWING THE DRIVER'S SEAT TO UNEXPECTEDLY DROP TO THE FLOOR WITHOUT WARNING.
Risk: IN THE EVENT THIS SHOULD OCCUR WHILE THE BUS IS IN OPERATION, THE DRIVER MAY LOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH.
Fix: MCI WILL NOTIFY OWNERS AND REPLACE THE SEAT SHOCK AS NECESSARY FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 15, 2010. OWNERS MAY CONTACT MCI CUSTOMER SERVICE AT 1-800-241-2947.
Service bulletins (5)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Service Brakes, Hydraulic 2021-12-14 · TSIB 21-01 · Service Bulletin/Repair Instructions
this technical service information bulletin (tsib) describes an update from meritor for the bolt torque application requirements on hub-to-rotor bolts for the front, drive and tag axles, on specific coaches equipped with meritor ex225 disc brakes, on either conventional, preset or unitized wheel-end
Equipment 2020-09-17 · SB 3139 · Service Bulletin/Repair Instructions
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.
Electrical System 2019-10-07 · SB 3120 · Service Bulletin/Repair Instructions
this service bulletin informs owners of the procedure to clean the batteries and reapply corrosion inhibitor every 6000 miles or 3 months, whichever first occurs.
Unknown Or Other 2011-04-25 · SB-357 · Service Bulletin/Repair Instructions
motor coach indudstries: information on replacing the coolant pump that may have a problem. *rm
Power Train:manual Transmission 2011-02-24 · 354 · Service Bulletin/Repair Instructions
motor coach industries service campaign: see document search button for owner letter. there may be a harsh downshift, rpm flare, or the transmission may lock. *rm
What owners report
No detailed complaint narratives on file.
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.