Defect: Motor Coach Industries (MCI) is recalling certain 2024 D45CRTE, D45CRTELE, and 2025 J4500E coaches. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity. (excerpt)
Consequence: A short circuit in a high voltage battery increases the risk of a fire. (excerpt)
Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. MCI will either replace the batteries, repurchase the vehicles, offer a vehicle trade-in or a reimbursement, free of charge. Owner notification letters were mailed June 8, 2026. Owners may contact MCI customer service at 1-800-241-2 (excerpt)
Defect: Motor Coach Industries (MCI) is recalling certain 2020-2021 J4500E, 2021 D45CRTELE, 2023 J4500E, 2023-2024 D45CRTELE, 2024 D45CRTE, and 2025 J4500E buses. An inadequate weld on the high voltage battery busbar and incorrect software may cause the battery module to overheat.
Consequence: A battery module that overheats increases the risk of a fire.
Remedy: MCI will inspect and replace the battery module as necessary. MCI will also update the BMS software. Owner notification letters were mailed October 6, 2025. Owners may contact MCI customer service at 1-800-241-2947.
Do not drive: No. Park outside: No.
Investigations
0 investigations; 0 open.
Manufacturer communications
9 manufacturer communications.
Communications by system
System
Count
ELECTRICAL SYSTEM
5
FUEL/PROPULSION SYSTEM
4
STEERING
2
SERVICE BRAKES
1
SUSPENSION
1
11036144
Date: 2026-08-11. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM, SERVICE BRAKES.
This bulletin is to provide instructions for clearing DTC 1067 FMI 7 (Pressure Sensor Not Calibrated) and FMI 11 (Primary and Secondary Circuit Pressure Sensor (PS1/PS2) Plausibility Error - BS Pressure), when required to prevent the loss of Adaptive Cruise Control functionality and the illuminatio
11032280
Date: 2026-05-06. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM.
This TSIB provides information to provide a software update. Some coaches using MCC HVAC Eco-Tempo ECU # 07-10-009 software T35-1581 / V1.04 may be experiencing random fault codes due to MCC software errors.
11029031
Date: 2026-02-09. Type: Service Bulletin/Repair Instructions. Systems: STEERING, SUSPENSION.
This TSIB is to inform customers the recommended steering axle cleaning/greasing instructions to prevent damage on axle components due to displacement of grease from the bearings, lubrication reduction and accelerate wear for coaches with independent front suspension.
11025741
Date: 2025-11-24. Type: Service Bulletin/Repair Instructions. Systems: FUEL/PROPULSION SYSTEM.
Instructions to replace the MDS (Main Disconnect Switch) decal from a 1-minute wait with a 5-minute wait time to allow the Battery Management System (BMS) to shut down.
A consumer notification indicating one of New Flyer's battery suppliers is exiting the market.
11024489
Date: 2025-10-15. Type: Service Bulletin/Repair Instructions. Systems: STEERING.
MCI noticed that some customers operating in severe duty environments were experiencing the exterior U-Joints of the lower steering shaft binding due to corrosion. Because of this, MCI has developed a new re-greaseable U-Joint service kit (NF PN: 6505981) to replace the existing greased for life U-J
This Bulletin is being issued due to New Flyer & MCI have received reports that customers are re-torquing high-voltage (HV) connections during preventative maintenance inspections as outlined in the Preventive Maintenance section of the Service or Maintenance manual. This Bulletin reminds operators
11019284
Date: 2025-05-21. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM.
This bulletin outlines steps to replace the existing harness with mini fuses in the battery compartment for the condensers to a more robust design.
11018239
Date: 2025-05-06. Type: Service Bulletin/Repair Instructions. Systems: FUEL/PROPULSION SYSTEM.
Instructions to replace the BTMS coolant filter and filter head due to possible damage from galling.
Notes on this record
Complaints from the API and bulk file are merged and deduplicated by ODI number; the API alone misses records.
System and subsystem counts are numbers of distinct complaints, recalls or communications that name them. One record can name several systems, so shares across systems can add to more than 100 percent; a single share never exceeds 100 percent.
Recalls are counted once per campaign, investigations once per action and manufacturer communications once per NHTSA id, even when NHTSA lists several model names for the same record.
A sales denominator is a calendar-year proxy, not the population of vehicles still in use. Rates are copied from verified pipeline output.
NHTSA's complaints API and bulk file list no complaint for this make, model and model year in this data build.