2009 Mci D4005 Recalls

Recalls on record Updated July 2026

The 2009 Mci D4005 has 4 NHTSA recall campaigns affecting an estimated 27,537 vehicles. Recall repairs are always free at any authorized dealer. Last updated July 5, 2026.

Recall campaigns

VISIBILITY 25V853000 2025-12-10 15,454 affected
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…

Consequence

The incorrect window glazing material may reduce the driver's visibility, increasing the risk of a crash.

Remedy

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 13V498000 2013-10-17 10,016 affected
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…

Consequence

Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

Remedy

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) 11V524000 2011-10-26 1,962 affected
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…

Consequence

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.

Remedy

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 10V409000 2010-09-09 105 affected
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.

Consequence

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.

Remedy

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.

Defect investigations

Investigation EA12007 Opened 2012-09-13 · closed 2015-12-03

MCI Drive Shaft Safety Loop Failures

In the fall of 2011, network contacts made ODI aware of four (4) incidents of drive shaft failure on the subject buses involving a loss of vehicle control.Two of the incidents were relatively low speed non-crash events; and two resulted in motor coach rollovers.All four events showed signs of a common failure…

Investigation EA12007 Opened 2012-09-13 · closed 2015-12-03

MCI Drive Shaft Safety Loop Failures

In the fall of 2011, network contacts made ODI aware of four (4) incidents of drive shaft failure on the subject buses involving a loss of vehicle control.Two of the incidents were relatively low speed non-crash events; and two resulted in motor coach rollovers.All four events showed signs of a common failure…

Investigation EA12007 Opened 2012-09-13 · closed 2015-12-03

MCI Drive Shaft Safety Loop Failures

In the fall of 2011, network contacts made ODI aware of four (4) incidents of drive shaft failure on the subject buses involving a loss of vehicle control.Two of the incidents were relatively low speed non-crash events; and two resulted in motor coach rollovers.All four events showed signs of a common failure…

Investigation PE09042 Opened 2009-09-01 · closed 2009-12-08

ALTERNATOR CABLE CHAFING

THIS INVESTIGATION WAS PROMPTED BY A REVIEW OF SERVICE BULLETINS PROVIDED BYMCI TO THE AGENCY. MOTOR COACH INDUSTRIES (MCI) SUBMITTED A SERVICE BULLETIN/PRODUCT IMPROVEMENT CAMPAIGN (#3016) IN THEIR 579.5 MONTHLY SUBMISSION REGARDING AN ALTERNATOR CABLE CHAFING ISSUE ON D SERIES COACHES EQUIPPED WITH A CATERPILLAR…

Investigation PE12007 Opened 2012-03-21 · closed 2012-09-20

MCI Driveshaft Safety Loop Failures

ODI has identified certain MCI coaches with powertrain configurations that may allow a driveshaft separated at the rearward universal joint to escape the guardian structure of the steerable tag axle and damage steering and braking components.The damaged components may increase the risk of a loss of vehicle control.…

Investigation PE12007 Opened 2012-03-21 · closed 2012-09-20

MCI Driveshaft Safety Loop Failures

ODI has identified certain MCI coaches with powertrain configurations that may allow a driveshaft separated at the rearward universal joint to escape the guardian structure of the steerable tag axle and damage steering and braking components.The damaged components may increase the risk of a loss of vehicle control.…

Investigation PE12007 Opened 2012-03-21 · closed 2012-09-20

MCI Driveshaft Safety Loop Failures

ODI has identified certain MCI coaches with powertrain configurations that may allow a driveshaft separated at the rearward universal joint to escape the guardian structure of the steerable tag axle and damage steering and braking components.The damaged components may increase the risk of a loss of vehicle control.…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2009 Mci D4005 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.