2012 Mci D4000 problems, complaints & recalls

Defect: Motor Coach Industries (MCI) is recalling certain 2011-2016 D4500, D4505, D4000, D4005, and D4000 ISTV motor coaches equipped with ISX engines. Due to vibrations, the exhaust bellow pipes develop a hole.

Risk: If the pipe develops a hole, during a regeneration cycle, hot exhaust gases may leak out, increasing the risk of a fire.

Fix: MCI will notify owners, and dealers will replace the bellows pipe assembly with an improved part, free of charge. The recall began July 10, 2018. Owners may contact MCI customer service at 1-800-241-2947.

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.

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.

Defect: Motor Coach Industries (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured November 12, 2011, to July 11, 2012, and 2014-2015 D4500 motorcoaches manufactured July 4, 2014, to April 30, 2015. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.

Risk: If the engine oil comes into contact with a hot surface, it can increase the risk of a vehicle fire.

Fix: MCI will notify owners, and Cummins service centers will administer the repairs which include securing the ends of the 90-degree elbow and reprogramming the electronic control module (ECM) with software that can adjust the engine output under misfire conditions to limit crankcase pressures. These repairs will be performed free of charge. The recall began on June 18, 2015. Owners may contact MCI customer service at 1-800-241-2947 or Cummins Inc. at 1-800-343-7357. MCI's number for this recall

Defect: Motor Coach Industries, Inc. (MCI) is recalling certain model year 2011-2012 D4000 motorcoaches manufactured March 2011 through July 2012 and equipped with certain Cummins Westport model ISL G. Condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold pressure sensor.

Risk: The improper operation of the sensor could induce elevated exhaust temperatures or flames from the exhaust pipe, increasing the risk of a vehicle fire or burn injury to a person near the exhaust pipe.

Fix: MCI will notify owners, and authorized Cummins service facilities will upload a new ECM calibration, free of charge. The recallbegan on April 16, 2014. Customers may contact MCI at 1-847-285-2090 or Cummins Inc. at 1-800-343-7357. MCI's number associated with this campaign is 405.

Defect: Motor Coach Industries (MCI) is recalling certain model year 2012-2013 D4000, D4000ISTV, D4005, D4500, and D4505 motorcoaches manufactured from May 2012 through December 2012 and equipped with a Cummins ISX EPA 2010 engine. In the affected buses, the bellows pipe in the exhaust system may have been incorrectly assembled, which could result in a failure of the pipe during operation.

Risk: During a regeneration process to clean exhaust emissions, if the bellows pipe has failed, the hot exhaust gases may not be contained, resulting in a fire.

Fix: MCI will notify owners and dealers will inspect and replace the bellows pipes, as necessary, free of charge. The recall began on April 29, 2013. Customers may contact MCI at 1-847-285-2000.

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.