RoadVitals

2002 Mci G4500

Recalls, owner-reported complaints, investigations and safety data

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
0
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
8
Latest Sep 2, 2009
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
3
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
0

Overview

Our database contains no NHTSA owner-reported complaints for the 2002 Mci G4500. 8 safety recalls have been issued covering this model year; 3 NHTSA investigations name it; and 4 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Safety recalls

8 campaigns cover this model year

View all 8

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
09V345000

STRUCTURE:BODY:DOOR

Sep 2, 2009
352 units potentially affected
The defect: 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.
The risk: 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.
The remedy: 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.
MOTOR COACH INDUSTRIES, INCView on NHTSA.gov
08V121000

SUSPENSION:REAR:AXLE:NON-POWERED AXLE ASSEMBLY

Mar 18, 2008
542 units potentially affected
The defect: MCI IS RECALLING 542 MY 2000-2004 G4100 AND G4500 MOTOR COACHES. CERTAIN REWORKED TAG AXLE ARM ASSEMBLIES HAD BEEN IDENTIFIED WITH NEW CRACKS FORMING. SOME OF THE TAG AXLE ARM ASSEMBLIES THAT HAD PREVIOUSLY BEEN REPAIRED DURING RECALLS 03V-411 OR 06V458 MAY HAVE BEEN REPAIRED WITH UNIDENTIFIED MICRO FRACTURES AND/OR INSUFFICIENT WELD PENETRATION.
The risk: IF THE TAG AXLE SWING ARM CRACKS AND REMAINS UNDETECTED, THE CRACKS CAN SPREAD AND POTENTIALLY RESULT IN A PARTIAL OR TOTAL SEPARATION OF THE TAG AXLE ASSEMBLY FROM THE COACH, INCREASING THE RISK OF A CRASH.
The remedy: DEALERS WILL RE-INSPECT AND IF CRACKS ARE IDENTIFIED OR INCORRECT WELDS IN THE PREVIOUSLY REPAIRED AREAS, BOTH RIGHT AND LEFT TAG ARM ASSEMBLIES WILL BE REPLACED. IF NO PROBLEMS ARE IDENTIFIED, DEALERS WILL REINSTALL THE EXISTING TAG AXLE ARM ASSEMBLIES WITH NEW HARDWARE FREE OF CHARGE. PLEASE NOTE THAT THIS CAMPAIGN SUPERSEDES MCI'S PREVIOUS RECALLS (PLEASE SEE 03V411 AND 06V458). THE RECALL BEGAN ON MARCH 18, 2008. OWNER MAY CONTACT MOTOR COACH AT 1-800-241-2947.
MOTOR COACH INDUSTRIES, INCView on NHTSA.gov
07V096000

STEERING:GEAR BOX (OTHER THAN RACK AND PINION)

Mar 5, 2007
518 units potentially affected
The defect: ON CERTAIN MOTOR COACHES, A WELD JOINING A GUSSET SUPPORT FROM THE FRONT BOGIE LEG TO THE STEERING BOX MOUNTING PLATE CAN CRACK.
The risk: THIS CAN ALLOW ADDITIONAL MOVEMENT OF THE MOUNTING PLATE IN DRY STEER APPLICATIONS AND AT THE EXTREME OUTWARD STEERING POSITIONS INCREASING THE RISK OF A CRASH.
The remedy: DEALERS WILL INSTALL AN ADDITIONAL GUSSET TO THESE ASSEMBLIES AND REWELD AS REQUIRED. THE RECALL BEGAN ON MARCH 23, 2007. OWNERS MAY CONTACT MOTOR COACH AT 1-800-241-2947.
MOTOR COACH INDUSTRIES, INCView on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

PE09038ClosedPreliminary Evaluation

WHEEL CHAIR DOOR BECOMES UNLATCHED

Opened Aug 28, 2009
Closed Nov 5, 2009

THIS INVESTIGATION WAS PROMPTED BY A REVIEW OF SERVICE BULLETINS PROVIDED BYMCI TO THE AGENCY. MCI SUBMITTED A FIELD CHANGE PROGRAM BULLETIN IN THEIR JULY 2009 MONTHLY COMMUNICATIONS (49 CFR 597.5) SUBMISSION REGARDING A WHEELCHAIR LIFT INTERLOCK DOOR RETROFIT KIT FOR G4500 SERIES COACHES.PER THE BULLETIN, THE SLIDING WHEELCHAIR DOOR MAY BECOME UNLATCHED, THE VISUAL WARNING INDICATOR IN THE DRIVER'S AREA MAY GO UNNOTICED BY THE DRIVER AND THERE IS NO AUDIBLE WARNING.DURING THE REVIEW PROCESS, ODI LEARNED OF ACOMPLAINT FROM AN INDIVIDUAL WHOSE GROUP CHARTERED A G4500 MOTORCOACH AND REPORTEDLY THE WHEELCHAIR ACCESS DOOR ON THE RIGHT SIDE OF THE BUS OPENED WHILE THE BUS WAS TRAVELING ON THE HIGHWAY AT 55 MPH.THE INVESTIGATION WAS OPENED TO ASSESS THE SCOPE AND SAFETY CONSEQUENCE OF THIS ISSUE.IN SEPTEMBER 2009, MCI FILED A SAFETY RECALL (09V-345) OUTLINING THEIR INTENDED REMEDY PROGRAM TO RESOLVE THIS ISSUE. MCI WILL ADD AN AUDIBLE ALARM TO ALERT THE DRIVER THAT THE DOOR IS NOT FULLY LATCHED. THEY ALSO INTEND TO REINFORCE THE UPPER DOOR LATCH TO IMPROVE LATCHING SYSTEM DURABILITY.THE ACTION TAKEN BY MCI RESOLVES THE ISSUES RAISED BY THIS INVESTIGATION. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.

STRUCTURE:BODY:DOORLed to recall 09V345000
PE06051ClosedPreliminary Evaluation

STEERING BOX MOUNTING BRACKET CRACK

Opened Nov 13, 2006
Closed Mar 22, 2007

THIS INVESTIGATION WAS OPENED AFTER ODI WAS CONTACTED BY A FLEETALLEGING THAT THEY HAVE HAD NINE INCIDENTS WHERE CRACKS WERE FOUND IN THE BRACKET THAT SUPPORTS THE STEERING GEAR BOX ASSEMBLY.THESE CRACKS WERE ALLOWING MOVEMENT OF THE STEERING BOX.ODI WAS CONCERNED THAT SHOULD THIS BRACKET COMPLETELY FAIL WHILE THE BUS IS BEING DRIVEN, A LOSS OF STEERING WOULD OCCUR.AS A RESULT OF ODI'S INVESTIGATION, MCI HAS AGREED TO INITIATE A SAFETY RECALL TO ADD AN ADDITIONAL GUSSET TO THE BRACKETS AND REWELD AS NECESSARY. THE TARGET DATE FOR LAUNCHING THE CORRECTIVEACTION ISMARCH 31, 2007.MCI'S ACTIONRESOLVES THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED. THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION ON THESE VEHICLES IF WARRANTED IN THE FUTURE.

STEERINGLed to recall 07V096000
RQ06008ClosedRecall Query

FAILED TAG AXLE SWING ARMS

Opened Sep 5, 2006
Closed Jan 17, 2007

MCI ORIGINALLY FILED A DEFECT NOTIFICATION ON OCTOBER 20, 2003, (03V-411) TO ADDRESSCRACKS LOCATED ON THE TAG AXLE SWING ARM AT THE CONNECTION TO THE PIVOT SPINDLE TUBE.FOUR HUNDRED AND NINETY-THREE (493) MCI G4500 2000-2003 MOTOR COACHES WERE INVOLVED.MCI?S ENGINEERING ANALYSIS DETERMINED THAT INSUFFICIENT WELD METAL AND /OR WELD PENETRATION ON THE FAILED COMPONENTS COULD RESULT IN EARLY STRESS AND FATIGUE CRACKS AT A WELD JOINING THE TAG AXLE TO THE PIVOT TUBE ASSEMBLY.MCI'S FIELD REPAIR CONSISTED OF INSPECTING AND RE-WELDING THE TAG AXLE SWING ARM.A SMALL PERCENTAGE WERE NOT REPAIRABLE AND REQUIRED A FULL REPLACEMENT OF THE SWING ARM. ON JULY 18, 2006, ODI WAS CONTACTED BY A FLEETALLEGING THAT THEY HAD THREE TAG AXLE ARMS CRACK AND SUBSEQUENTLY BREAK IN THE SAME AREA REPAIRED BY MCI DURING THE SAFETY RECALL.AS A RESULT, ODI OPENED THIS RQ.MCI CONDUCTED FURTHER ANALYSIS AND DETERMINED THAT SOME OF THE PREVIOUSLY REPAIRED SWING ARMS, REPAIRED DURING RECALL 03V-411 MAY HAVE BEEN REPAIRED WITH EXISTING UNIDENTIFIED MICRO-FRACTURES AND/OR WELDS WITH INSUFFICIENT PENETRATION.THIS COULD LEAD TO FURTHER CRACKING AND RESULT IN A PARTIAL OR TOTAL SEPARATION OR THE TAG ARM. AS A RESULT OF THIS INVESTIGATION, MCI HAS ANNOUNCED A NEW SAFETY RECALL IN WHICH THEY WILL REPLACE ALL THE TAG ARMS WITH A NEWLY DESIGNED TAG AXLE SWING ARM.MCI'S NEW RECALL ACTIONRESOLVES THIS INVESTIGATION.THEREFORE, THIS INVESTIGATION IS CLOSED.ODI WILL CONTINUE TO MONITOR THE PROGRESSION OF THE NEW RECALL BEING CONDUCTED BY MCI.

SUSPENSION:FRONT:CONTROL ARMLed to recall 06V458000

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

No owner complaints recorded for this model year

Either none have been filed with NHTSA, or this vehicle is too new for reports to have accumulated.

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

SB-357

MOTOR COACH INDUDSTRIES: INFORMATION ON REPLACING THE COOLANT PUMP THAT MAY HAVE A PROBLEM. *RM

354

POWER TRAIN:AUTOMATIC TRANSMISSION; POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM); POWER TRAIN:MANUAL TRANSMISSION

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

SB-3042

EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

MCI: TAG AXLE R-12 BRAKE VALVE RETROFIT MAY BE SUBJECT TO CONTAMINATION INTRUSION THROUGH THE BALANCE PORT. INSTALLING A R-12 BRAKE VALVE, WHICH DOES NOT HAVE A BALANCE PORT, WILL ELIMINATE THE POTENTIAL FOR CONTAMINATION. NO MODEL OR MODEL YEARS LISTED. *PE

SB-3037

STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS

MCI: BOGIE LEG FRAME CORROSION PREVENTION. NEW AND VERY CORROSIVE FORMULATIONS OF ROAD ICE CLEANING CHEMICALS ARE NOW BEING USED, ESPECIALLY MAGNESIUM CHLORIDE AND CALCIUM CHLORIDE. THESE CHEMICALS CAN ACT LIKE ACID WHEN THEY CONTACT THE EXPOSED METAL PORTIONS OF VEHICLES. MODEL G SERIES. NO MODEL YEARS LISTED. *PE

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Mci G4500 by model year
YearComplaintsRecallsInvestigationsIssue Index
2004063—
2003083—
2002Viewing083—
2001083—
2000022—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.