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. (excerpt)
Consequence: 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. (excerpt)
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 BE (excerpt)
Defect: ON CERTAIN G4500 MOTOR COACHES, THE TAG AXLE SWING ARM CAN BREAK AWAY.
Consequence: 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.
Remedy: PLEASE NOTE THAT THIS CAMPAIGN HAS BEEN SUPERSEDED BY 08V121.
Do not drive: No. Park outside: No.
Investigations
2 investigations; 0 open.
PE06051
Opened: 2006-11-13. Closed: 2007-03-22.
STEERING BOX MOUNTING BRACKET CRACK
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 INVESTIGATI
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 A
Date: 2011-04-25. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
MOTOR COACH INDUDSTRIES: INFORMATION ON REPLACING THE COOLANT PUMP THAT MAY HAVE A PROBLEM. *RM
10038195
Date: 2011-02-24. Type: Service Bulletin/Repair Instructions. Systems: POWER TRAIN.
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
10034007
Date: 2010-06-03. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT, UNKNOWN OR OTHER.
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
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.