Motor Coach Industries, Inc: Safety Recalls in 2009
Updated on March 19, 2026.
There were 8 safety recalls made by Motor Coach Industries, Inc in 2009. See the details of the recalls below.
You can also see similar information for other manufacturers.
Data Source: NHTSA.
November 18, 2009
(Campaign #: NR (Not Reported))
ALTERNATOR CABLE ASSEMBLY
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.
NHTSA ID: 09V446000
Component: ELECTRICAL SYSTEM
# of Units Affected: 1,007
Consequence Summary:
THIS COULD RESULT IN A FIRE.
Corrective Action:
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.
Park Outside Advisory: No
Do not Drive Advisory: No
November 3, 2009
(Campaign #: 335)
HORIZON LED SIDE DESTINATION SIGN/LUMINATOR
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.
NHTSA ID: 09V432000
Component:
# of Units Affected: 701
Consequence Summary:
A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.
Corrective Action:
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.
Park Outside Advisory: No
Do not Drive Advisory: No
September 9, 2009
(Campaign #: 331B)
TAG AXLE TIE ROD CLAMPS
MCI IS RECALLING MODEL YEAR 2009 D4500/4505 COACHES EQUIPPED WITH THE MERITOR FH 946 14,000 LB RATED STEERABLE TAG AXLE. DUE TO INSUFFICIENT CLAMPING FORCE OF THE CYLINDER LOCK PLATE, IT MAY MOVE FROM ITS NORMAL SET POSITION, WHICH IN TURN COULD RESULT IN THE TAG AXLE NOT AUTOMATICALLY LOCKING, OR LOCKING WITH THE WHEELS NOT IN A STRAIGHT AHEAD POSITION.
NHTSA ID: 09V350000
Component: STEERING
# of Units Affected: 53
Consequence Summary:
IF THE TAG AXLE DOES NOT LOCK ABOVE 20 MPH, THERE IS A LOSS OF LATERAL FORCE CONTROL OF THE TAG AXLE THAT CAN AFFECT THE STEERING OF THE VEHICLE. ALSO DURING A TURN THE REAR OF THE VEHICLE WILL SWING FURTHER OUT IN THE OPPOSITE DIRECTION OF THE TURN AND COULD RESULT IN THE COACH STRIKING ANOTHER VEHICLE INCREASING THE RISK OF A CRASH.
Corrective Action:
DEALERS WILL PROVIDE REPLACEMENT CLAMPS THAT DO NOT HAVE PAINT ON THE CLAMPING SURFACES. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 14, 2009. OWNERS MAY CONTACT MCI CUSTOMER SERVICE LINE AT 1-800-241-2947.
Park Outside Advisory: No
Do not Drive Advisory: No
September 2, 2009
(Campaign #: NR (Not Reported))
WHEELCHAIR DOOR BECOMES UNLATCHED
MCI IS RECALLING MODEL YEAR 2001-2004 G4500 MOTOR COACHES EQUIPPED WITH WHEELCHAIR LIFTS. IF THE UPPER WHEELCHAIR DOOR OPENS DUE TO A MALFUNCTION OF THE DOOR'S LATCHES, THERE IS A TELLTALE LIGHT IN THE INSTRUMENT PANEL THAT ILLUMINATES TO ALERT THE DRIVER THAT THE UPPER WHEELCHAIR DOOR IS NOT FULLY LATCHED AND CLOSED, HOWEVER THE DRIVER COULD FAIL TO NOTICE THAT THIS LIGHT IS ILLUMINATED.
NHTSA ID: 09V345000
Component: STRUCTURE
# of Units Affected: 352
Consequence Summary:
THIS COULD RESULT IN THE WHEELCHAIR DOOR SLIDING OPEN WITHOUT FURTHER WARNING AND EXPOSE PASSENGERS TO THE RISK OF FALLING FROM THE COACH WHILE THE VEHICLE IS IN MOTION.
Corrective Action:
DEALERS WILL INSTALL AN AUDIBLE ALARM IN THE DRIVER'S AREA TO PROVIDE AN ADDITIONAL ALERT IN THE EVENT THE DOOR IS NOT FULLY CLOSED AND LATCHED, AND WILL REINFORCE THE UPPER LATCH TO IMPROVE ITS DURABILITY. THE RECALL BEGAN ON SEPTEMBER 4, 2009. OWNERS MAY CONTACT MCI CUSTOMER SERVICE LINE AT 1-800-241-2947.
Park Outside Advisory: No
Do not Drive Advisory: No
June 8, 2009
(Campaign #: FCP 329)
SHOCK ABSORBER SEPARATION/KONI
MCI IS RECALLING 29 MODEL YEAR 2009 D4505 MOTOR COACHES MANUFACTURED BETWEEN FEBRUARY AND APRIL 2009, EQUIPPED WITH KONI SHOCK ABSORBERS. WHEN THE COACH IS MOVING IN REAR-RISE MODE, THE TAG SUSPENSION AIR SPRINGS CAN GENERATE FORCE THAT EXCEEDS THE MAXIMUM ALLOWABLE TENSILE STRENGTH OF THE SHOCK ABSORBERS EXCEEDING THEIR DESIGN REBOUND LIMIT.
NHTSA ID: 09V200000
Component: SUSPENSION
# of Units Affected: 29
Consequence Summary:
THIS FAILURE COULD RESULT IN SEPARATION OF THE SHOCK ABSORBER FROM ITS MOUNTING, CAUSING INTERFERENCE BETWEEN THE UPPER PORTION OF THE SUSPENSION AND THE DRIVESHAFT, POSSIBLY RESULTING IN A VEHICLE CRASH.
Corrective Action:
MCI WILL NOTIFY OWNERS AND WILL REPAIR THE COACHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JULY 10, 2009. OWNERS MAY CONTACT MCI AT 1-847-285-2000.
Park Outside Advisory: No
Do not Drive Advisory: No
June 1, 2009
(Campaign #: 327 & 328)
STEERING ANGLE SENSOR FAILURE/MERITOR WABCO
MCI IS RECALLING CERTAIN MODEL YEAR 2008 AND 2009 MOTOR COACHES, MODEL J4500 MANUFACTURED BETWEEN OCTOBER 2007 AND APRIL 2009; 2009 MOTOR COACHES MODELS D4000ISTV, D4005, D4500, AND D4505 MANUFACTURED BETWEEN JANUARY AND JULY 2009; 2010 D4500 COACHES MANUFACTURED BETWEEN DECEMBER 2008 AND APRIL 2009; 2009 E4500 COACHES MANUFACTURED BETWEEN JANUARY AND APRIL 2009; AND ONE 2003 E4500 COACH MANUFACTURED IN OCTOBER 2002. THESE VEHICLES MAY HAVE BEEN EQUIPPED WITH MERITOR WABCO STEERING ANGLE SENSORS (SAS) WHICH CAN DEVELOP INTERNAL FRICTION BETWEEN THE SENSOR GEARS AND THE SENSOR HOUSING AS A RESULT OF EXTERNAL FORCES EXPERIENCED ON THE VEHICLE INCLUDING VIBRATION. IF DEVELOPED FRICTION IS GREAT ENOUGH, THE DRIVING TAB OF THE SAS CAN SHEER AS THE DRIVER TURNS THE STEERING WHEEL.
NHTSA ID: 09V196000
Component:
# of Units Affected: 502
Consequence Summary:
WITH A BROKEN SAS DRIVING TAB, THE ELECTRONIC STABILITY CONTROL (ESC) WILL NOT FUNCTION PROPERLY, WHICH COULD POSSIBLY RESULT IN A VEHICLE CRASH.
Corrective Action:
MCI WILL NOTIFY OWNERS AND THE VEHICLES WILL BE REPAIRED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JULY 10, 2009. OWNERS MAY CONTACT MCI AT 1-800-241-2947.
Park Outside Advisory: No
Do not Drive Advisory: No
April 8, 2009
(Campaign #: NR (Not Reported))
ATC/ESC VALVES
MCI IS RECALLING 316 MY 2008-2009 J4500 COACH VEHICLES. THESE VEHICLES MAY CONTAIN A DISTORTED VALVE IN THE AUTOMATIC TRACTION CONTROL (ATC) AND/OR ELECTRONIC STABILITY CONTROL (ESC) SYSTEMS. UNDER CERTAIN CONDITIONS, THE VALVE MAY STICK IN THE OPEN POSITION AND CAUSE FULL SERVICE BRAKE PRESSURE TO BE APPLIED TO EITHER THE FRONT AXLE BRAKES OR THE DRIVE AND TAG AXLE BRAKES, DEPENDING ON WHETHER THE DISTORTED VALVE IS A FRONT OR REAR VALVE.
NHTSA ID: 09V115000
Component: SUSPENSION
# of Units Affected: 316
Consequence Summary:
IN THE EVENT THE VALVE STICKS IN AN OPEN POSITION AND CAUSES FULL SERVICE BRAKE PRESSURE TO BE APPLIED, A VEHICLE MAY EXPERIENCE BRAKE LOCK-UP ONCE THE VEHICLE SLOWS TO 5 MPH, THEREBY INCREASING THE RISK OF A CRASH.
Corrective Action:
DEALERS WILL INSPECT AND REPLACE THE ATC VALVES FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING MAY 2009. OWNERS MAY CONTACT MCI AT 847-285-2000.
Park Outside Advisory: No
Do not Drive Advisory: No
February 3, 2009
(Campaign #: 277C & 320)
TAG AXLE DRIVESHAFT INTERFERENCE
MCI IS RECALLING 103 MY 2005-2008 D4500 AND D4505 COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES AND A ZF TRANSMISSION. CUSTOMERS MAY EXPERIENCE A POSSIBLE INTERFERENCE BETWEEN THE DRIVE SHAFT U-JOINT BEARING CAP BOLTS AND THE TAG AXLE CENTER BEAM ASSEMBLY.
NHTSA ID: 09V041000
Component: SUSPENSION
# of Units Affected: 103
Consequence Summary:
INTERFERENCE BETWEEN THE BEARING CAP BOLTS AND THE AXLE CENTER BEAM ASSEMBLY COULD CAUSE THE BEARING CAP BOLTS TO SHEAR, FREEING THE BEARINGS AND POSSIBLY RELEASING THE DRIVE SHAFT, INCREASING THE RISK OF VEHICLE DAMAGE OR A CRASH.
Corrective Action:
DEALERS WILL INSTALL A TAG AXLE SUSPENSION SPACER KIT AND AN SPL250 DRIVESHAFT RETROFIT KIT TO LIMIT THE SUSPENSION TRAVEL AND REDUCE THE SWING DIAMETER OF THE DRIVESHAFT THEREBY INCREASING THE CLEARANCE AND ELIMINATING ANY POSSIBLE INTERFERENCE. THE RECALL BEGAN ON FEBRUARY 25, 2009. OWNERS MAY CONTACT MCI AT 1800-241-2947.
Park Outside Advisory: No
Do not Drive Advisory: No
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