No complaints are listed for the 2004 MCI G4500. NHTSA's API and bulk file list none in this build.
Data build 2026-10-08.
NHTSA lists this vehicle as MCI G4500.
Model-generated complaint tags: No complaints are listed for tagging.
Recalls
See new recalls and investigations this week.
6 recalls.
Date: 2013-10-17. Systems: ELECTRICAL SYSTEM.
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 insulation was found to be capable of conducting electricity after being exposed (excerpt)
Consequence: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire. (excerpt)
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. (excerpt)
Do not drive: No. Park outside: No.
Date: 2009-09-02. Systems: STRUCTURE.
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.
Consequence: 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.
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.
Do not drive: No. Park outside: No.
Date: 2008-03-18. Systems: SUSPENSION.
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)
Do not drive: No. Park outside: No.
Date: 2007-03-05. Systems: STEERING.
Defect: ON CERTAIN MOTOR COACHES, A WELD JOINING A GUSSET SUPPORT FROM THE FRONT BOGIE LEG TO THE STEERING BOX MOUNTING PLATE CAN CRACK.
Consequence: 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.
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.
Do not drive: No. Park outside: No.
Date: 2006-11-29. Systems: SUSPENSION.
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.
Date: 2006-04-27. Systems: ENGINE AND ENGINE COOLING.
Defect: ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.
Consequence: A FIRE CAN RESULT SHOULD THE TURBOCHARGER FAIL.
Remedy: DETROIT DIESEL IS CONDUCTING THIS RECALL (PLEASE SEE 06E019000) AND WILL REMEDY THESE MOTOR COACHES. THE ENGINES WILL BE REPAIRED FREE OF CHARGE. OWNERS MAY CONTACT DETROIT DIESEL AT 313-592-3708 OR MOTOR COACH AT 866-624-2622.
Do not drive: No. Park outside: No.
Investigations
3 investigations; 0 open.
PE09038
Opened: 2009-08-28. Closed: 2009-11-05.
WHEEL CHAIR DOOR BECOMES UNLATCHED
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
Systems: STRUCTURE.
Linked campaign numbers: 09V345000.
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
Systems: STEERING.
Linked campaign numbers: 07V096000.
RQ06008
Opened: 2006-09-05. Closed: 2007-01-17.
FAILED TAG AXLE SWING ARMS
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
Systems: SUSPENSION.
Linked campaign numbers: 06V458000.
Manufacturer communications
5 manufacturer communications.
Communications by system| System | Count |
|---|
| EQUIPMENT | 2 |
|---|
| UNKNOWN OR OTHER | 2 |
|---|
| POWER TRAIN | 1 |
|---|
| STRUCTURE | 1 |
|---|
10038824
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
10034009
Date: 2010-06-03. Type: Service Bulletin/Repair Instructions. Systems: STRUCTURE.
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 MO
10034191
Date: 2010-03-01. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT.
MCI: BEARING BOX. A NEW BREATHER VENT ASSEMBLY KIT FOR THE TAG AXLE BEARING BOX USED ON THE G SERIES COACHES. THE KIT INCLUDES A NEW BREATHER VENT AND AN EXTENSION WHICH RAISES THE BREATHER VENT ABOVE THE BEARING BOX TO REDUCE POTENTIAL PLUGGING OF THE BEARING BOX VENT AND INCREASING THE LUBRICAT