Mci 102DL3 recalls by model year

Reported: 2025-12-10 (December 10, 2025) · Model years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001

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 vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) number 205, "Glazing Materials."

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.

Reported: 1994-02-04 (February 4, 1994) · Model years: 1991, 1992, 1993

THE BRAKE ROD TO BRAKE ARM ATTACHING NUT AND BOLT ARE UNDERTORQUED AND MAY LOOSEN AND FALL OFF CAUSING SEPARATION OF THE ROD AND ARM.

Consequence: SEPARATION OF THE BRAKE ROD AND THE BRAKE ARM RESULTS IN THE TOTAL LOSS OF THE SERVICE BRAKES WHICH MAY RESULT IN AN ACCIDENT.

Remedy: MCI WILL SUPPLY 1/2" UNF "STOVER" LOCKNUT TO CUSTOMERS. THIS LOCKNUT SHOULD BE INSTALLED IMMEDIATELY AND TORQUED TO 40 LB/FT (54 NM). A FASTENER WILL ALSO BE PROVIDED TO THE CUSTOMER ALONG WITH THE INSTALLATION PROCEDURES.

Reported: 1993-01-22 (January 22, 1993) · Model years: 1992, 1993

THE BRACKETS USED TO RESTRAIN THE "REFERENCE-ZERO" ARM OF THE DRIVE AXLE SLACK ADJUSTERS MAY FLEX EXCESSIVELY, AND PREVENT SELF ADJUSTMENT OF THE SLACK ADJUSTERS. THIS COULD DEGRADE BRAKE EFFICIENCY AS THE BRAKE SHOES WEAR.

Consequence: DECREASED BRAKE EFFICIENCY COULD CAUSE INCREASED STOPPINGDISTANCES, WHICH COULD RESULT IN A VEHICLE ACCIDENT.

Remedy: A RETROFIT KIT IS TO BE INSTALLED TO CORRECT THE PROBLEM WITH THE ATTACHMENT BRACKETS.

Reported: 2014-06-18 (June 18, 2014) · Model years: 1993, 1994, 1995

Motor Coach Industries (MCI) is recalling certain model year 1993-1995 102DL3 motor coaches manufactured November 1992 to January 1995, and 2006 and 2008 D4505 motor coaches manufactured June 2005 to April 2008. The affected buses are equipped with a driveshaft with a compressed length of 30 inches or less, a steerable trailing axle equipped with a system that changes the tag axle caster when the vehicle is in reverse travel and no electronic stability control (ESC). In these vehicles, the driveshaft may detach from the transmission and escape its containment bracket.

Consequence: If the driveshaft escapes containment it can strike the trailing axle tie rod and components of the trailing axle locking system potentially causing the trailing axle steering and caster locking mechanisms to unlock. If this occurs, the driver may experience loss of steering control of the vehicle, increasing the risk of a vehicle crash.

Remedy: MCI will notify owners, and dealers will add a secondary drive shaft containment hoop forward of the tag axle support structure, free of charge. The recall began on August 7, 2014. Owners may contact MCI customer service at 1-847-285-2090. MCI's number for this recall is 414.

Reported: 1997-04-03 (April 3, 1997) · Model years: 1993, 1994, 1995, 1996, 1997

VEHICLE DESCRIPTION: BUSES EQUIPPED WITH 4-STROKE CYCLE ENGINES. ENGINE COMPARTMENT FIRES HAVE OCCURRED AT OR NEAR THE WEBASTO DIESEL FUELED AUXILIARY HEATER.

Consequence: PERSONAL INJURY AND PROPERTY DAMAGE CAN OCCUR DUE TO AN ENGINE COMPARTMENT FIRE.

Remedy: MCI IS ASKING COACH OPERATORS TO DISABLE THE WEBASTO HEATER BY DISCONNECTING THE APPROPRIATE FUSES.

Reported: 2006-12-19 (December 19, 2006) · Model years: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

ON CERTAIN MOTOR COACHES, THE BOOST CONNECTOR HOUSING CAN FAIL OVER TIME, EXPOSING THE POSITIVE AND NEGATIVE TERMINALS.

Consequence: THIS COULD RESULT IN THE GROUNDING OF AN UNPROTECTED CIRCUIT AND COULD LEAD TO A THERMAL EVENT IF NOT CORRECTED.

Remedy: CUSTOMERS ARE BEING ADVISED TO REMOVE THE BOOST CONNECTOR AND DISCARD IT. CUSTOMERS WILL BE OFFERED A NEW DESIGN BOOST CONNECTOR AS AN ALTERNATIVE AT NO COST. THE RECALL BEGAN ON JANUARY 2, 2007. OWNERS MAY CONTACT MCI AT 1-800-241-2947.

Reported: 2000-09-06 (September 6, 2000) · Model years: 1998, 1999, 2000

VEHICLE DESCRIPTION: MOTOR HOME CHASSIS BUILT WITH BENDIX AIR ABS WITH AN EC-17 1030R ELECTRONIC CONTROL UNIT (ECU), THERE HAVE BEEN REPORTS OF UNWANTED ABS ACTIVATION AT LOW SPEEDS CAUSED BY 1) CHAFED ABS WHEEL SPEED SENSOR WIRES ON ROTATING PARTS OR 2) A DAMAGED COMPONENT AT THE WHEEL END THAT GENERATES A CERTAIN TYPE OF ERRATIC SENSOR SIGNAL.

Consequence: THIS CONDITION COULD CAUSE THE ABS ECU TO EXHAUST THE AIR AT THE AIR BRAKE MODULATORS FOR ONE OR MORE OF THE WHEELS. THIS COULD RESULT IN EXTENDED BRAKING DISTANCES AND A POSSIBLE CRASH.

Remedy: DEALERS WILL REPLACE THE ABS ECU.

Reported: 2001-12-19 (December 19, 2001) · Model years: 1999, 2000

MOTORHOMES EQUIPPED WITH DRAG LINK ASSEMBLIES CONTAINING 20-EDL MODEL BALL SOCKETS AND MANUFACTURED BY TRW. CERTAIN OF THE TIE ROD BALL-SOCKET BEARINGS HAVE A BELOW-SPECIFICATION CASE DEPTH AND/OR HARDNESS, WHICH CAN LEAD TO PREMATURE WEAR OF THE SOCKET.

Consequence: IF THIS CONDITION OCCURS, THE DRIVER CAN LOSE PARTIAL CONTROL OF THE RIGHT FRONT WHEEL, POSSIBLY RESULTING IN A CRASH.

Remedy: DEALERS WILL REPLACE THE DEFECTIVE DRAG LINKS. OWNER/DISTRIBUTOR NOTIFICATION BEGAN APRIL 18, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT MCI AT 1-800-241-2941 OR TRW CUSTOMER SERVICE AT 1-866-280-3287.

Reported: 2013-10-17 (October 17, 2013) · Model years: 2000, 2001

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 to heat.

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.