2004 MCI G4500

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.

RiskOnce electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

FixMCI 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.

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.

RiskTHIS 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.

FixDEALERS 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.

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.

RiskIF 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.

FixDEALERS 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.

ON CERTAIN MOTOR COACHES, A WELD JOINING A GUSSET SUPPORT FROM THE FRONT BOGIE LEG TO THE STEERING BOX MOUNTING PLATE CAN CRACK.

RiskTHIS 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.

FixDEALERS 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.

ON CERTAIN G4500 MOTOR COACHES, THE TAG AXLE SWING ARM CAN BREAK AWAY.

RiskIF 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.

FixPLEASE NOTE THAT THIS CAMPAIGN HAS BEEN SUPERSEDED BY 08V121.

ON CERTAIN MOTOR COACHES EQUIPPED WITH DETROIT DIESEL SERIES 60 ENGINES, THE TURBOCHARGER COMPRESSORS CAN FAIL.

RiskA FIRE CAN RESULT SHOULD THE TURBOCHARGER FAIL.

FixDETROIT 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.

WHEEL CHAIR DOOR BECOMES UNLATCHED

Led to recall09V345000

STEERING BOX MOUNTING BRACKET CRACK

Led to recall07V096000

FAILED TAG AXLE SWING ARMS

Led to recall06V458000