2011 Mci D4005 problems, complaints & recalls
Safety recalls (5)
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.
Engine And Engine Cooling:exhaust System 2017-05-24 · campaign 17V337000 · 143 vehicles
Defect: Motor Coach Industries (MCI) is recalling certain 2011-2012 MCI D4000, D4005, D4500 and D4505 coaches equipped with Cummins ISX 12 liter engines. The vehicles may have an incorrectly installed exhaust bellow pipe, resulting in a bend in the pipe which can cause its premature failure.
Risk: If the pipe fails and a diesel regeneration cycle occurs, the hot exhaust gases will increase the risk of a fire.
Fix: MCI will notify owners and dealers will inspect and replace any deformed or failed bellow pipes if necessary, free of charge. The recall began on June 15, 2017. Owners may contact Motor Industries at 1-800-241-2947. MCI's number for this recall is SB 397B.
Seats 2016-01-20 · campaign 16V020000 · 607 vehicles
Defect: Motor Coach Industries (MCI) is recalling certain model year 2011-2013 and 2015 J4500 coaches manufactured November 18, 2011, to July 10, 2015, 2011-2012 and 2014-2015 D4000 coaches manufactured manufactured September 24, 2010, to September 5, 2015, 2011-2013 and 2015-2016 D4005 coaches manufactured January 17, 2011, to November 23, 2015, 2012-2014 and 2016 D4000ISTV coaches manufactured July 18, 2012, to December 2, 2015, 2010-2016 D4500 coaches manufactured April 15, 2010, to December 18, 2015
Risk: If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.
Fix: MCI will notify owners and dealers will inspect the seats and determined if welds are missing. Any J-Bracket that is missing welds will be removed and replaced, free of charge. The recall began on February 15, 2016. Owners may contact MCI at 1-800-241-2947. MCI's number for this recall is SB 431.
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.
Service bulletins (9)
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.
Seats 2022-05-03 · TSIB 22-03 · Service Bulletin/Repair Instructions
technical service information bulletin describing the replacement of seating backrest attachment hardware with the addition of a mechanical lock nut on specifically equipped buses manufactured prior to model year 2020.
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.
Engine And Engine Cooling 2019-10-22 · P08-54 · Service Bulletin/Repair Instructions
this procedure outlines the steps to install a relief valve on the air compressor for coaches equipped with dd13 engines.
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.
Suspension:front:shock Absorber 2014-05-07 · SB-407 · Service Bulletin/Repair Instructions
motor coach industries (mci): red 185 durometer polyurethane bushings were replaced with 288 polyurethane bushings in shock absorbers that in cold temperatures, will fail, causing absorber stud to break, at bushing, and coach is not operational due to risk of damage to suspension component. model
Showing the 6 most recent of 9 bulletins. Search all of them free at nhtsa.gov.
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.