2004 MCI G4500: recalls and complaints

NHTSA lists 6 recall campaigns for the 2004 MCI G4500. The newest campaign is 13V498000. NHTSA received the report on 17 Oct 2013. The NHTSA record gives the component Electrical System. NHTSA has no complaint on file for this model year. 3 NHTSA investigations name this model year.

The NHTSA recall file shows no do-not-drive advisory and no park-outside advisory on these campaigns.

This page cannot show if a recall applies to one vehicle. The NHTSA VIN lookup shows the unrepaired recalls of one vehicle.

Remedy of the newest campaign, 13V498000, in the NHTSA record

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.

NHTSA VIN lookup

Complaint information entered into NHTSA’s Office of Defects Investigation vehicle owner's complaint database is used with other data sources to identify safety issues that warrant investigation and to determine if a safety-related defect trend exists.
NHTSA publishes these words. Source: NHTSA Datasets and APIs, section Complaints, read on 1 Oct 2026. Complaint file through 30 Sep 2026. Recall file through 30 Sep 2026.

Since the last update

No tracked figure of this page changed in a data update. What the log tracks

All updates to the register

Recall campaigns

6 campaigns, newest first. 16,711 units in total.

13V49800017 Oct 2013Electrical System
09V3450002 Sep 2009Structure / Body / Door
08V12100018 Mar 2008Suspension / Rear / Axle / Non-Powered Axle Assembly
07V0960005 Mar 2007Steering / Gear Box (Other Than Rack and Pinion)
06V45800029 Nov 2006Suspension / Rear / Axle / Non-Powered Axle Assembly
06V14000027 Apr 2006Engine and Engine Cooling / Engine / Diesel

13V498000Received 17 Oct 2013. 10,016 units.
Electrical System
Defect, in the NHTSA record
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, in the NHTSA record
Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
Remedy, in the NHTSA record
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.
Report filed by Motor Coach Industries. Manufacturer campaign number 401. Owner notification date in the NHTSA record: 4 Feb 2014.
09V345000Received 2 Sep 2009. 352 units.
Structure / Body / Door
Defect, in the NHTSA record
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, in the NHTSA record
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, in the NHTSA record
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.
Report filed by MOTOR COACH INDUSTRIES, INC. Owner notification date in the NHTSA record: 4 Sep 2009.
08V121000Received 18 Mar 2008. 542 units.
Suspension / Rear / Axle / Non-Powered Axle Assembly
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
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, in the NHTSA record
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 began on march 18, 2008. Owner may contact motor coach at 1-800-241-2947.
Report filed by MOTOR COACH INDUSTRIES, INC. Owner notification date in the NHTSA record: 18 Mar 2008.
07V096000Received 5 Mar 2007. 518 units.
Steering / Gear Box (Other Than Rack and Pinion)
Defect, in the NHTSA record
On certain motor coaches, a weld joining a gusset support from the front bogie leg to the steering box mounting plate can crack.
Consequence, in the NHTSA record
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, in the NHTSA record
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.
Report filed by MOTOR COACH INDUSTRIES, INC. Owner notification date in the NHTSA record: 23 Mar 2007.
06V458000Received 29 Nov 2006. 518 units.
Suspension / Rear / Axle / Non-Powered Axle Assembly
Defect, in the NHTSA record
On certain g4500 motor coaches, the tag axle swing arm can break away.
Consequence, in the NHTSA record
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, in the NHTSA record
Please note that this campaign has been superseded by 08v121.
Report filed by MOTOR COACH INDUSTRIES, INC.
06V140000Received 27 Apr 2006. 4,765 units.
Engine and Engine Cooling / Engine / Diesel
Defect, in the NHTSA record
On certain motor coaches equipped with detroit diesel series 60 engines, the turbocharger compressors can fail.
Consequence, in the NHTSA record
A fire can result should the turbocharger fail.
Remedy, in the NHTSA record
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.
Report filed by MOTOR COACH INDUSTRIES, INC.

The campaign number opens the NHTSA record. Each quotation is the text of the NHTSA recall file.

Recall campaign: One recall in the NHTSA recall file, with one campaign number. A campaign can name many makes, models and model years.

Units: The number of vehicles or products that a recall can include. The manufacturer or the firm reports the number to the agency.

Complaints by component

The NHTSA complaint file has no complaint for this model year.

Investigations

NHTSA investigations that name the 2004 MCI G4500
Number	Type	Subject	Component	Opened	Closed	Campaign
PE09038	Preliminary evaluation	WHEEL CHAIR DOOR BECOMES UNLATCHED	Structure / Body / Door	28 Aug 2009	5 Nov 2009	09V345000
PE06051	Preliminary evaluation	STEERING BOX MOUNTING BRACKET CRACK	Steering	13 Nov 2006	22 Mar 2007	07V096000
RQ06008	Recall query	FAILED TAG AXLE SWING ARMS	Suspension / Front / Control Arm	5 Sep 2006	17 Jan 2007	06V458000

Investigation: A study of a possible safety defect by the NHTSA Office of Defects Investigation. An investigation with no closing date in the NHTSA file is open.

Other model years

The number under each year is the number of recall campaigns.

A year without a link has fewer than 2 campaigns and fewer than 25 complaints. It has no page.

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Official channels

NHTSA VIN lookupNHTSA shows the unrepaired recalls of one vehicle from its VIN or its license plate.
NHTSA: report a safety problemThe NHTSA form for a complaint about a vehicle, a tire, a child seat or equipment.
NHTSA page of the 2004 MCI G4500The recalls, the complaints and the investigations that NHTSA shows for this model year.

Cite this page

Recall Register. 2004 MCI G4500: recalls and complaints. https://recallregister.com/vehicle/mci/g4500/2004/. Source: NHTSA Office of Defects Investigation, recall, complaint and investigation files. Data through 30 Sep 2026.

Sources

Source: NHTSA Office of Defects Investigation
Licence: US government work, public domain
Recall file through: 30 Sep 2026
Complaint file through: 30 Sep 2026
First complaint in the file: 1 Jan 1995
Manufacturer in the recall file: Motor Coach Industries

The NHTSA record is the authority. A complaint count is the number of different complaint numbers for the make, the model and the model year. How the register is made. Report an error.

Questions

How many units are in the recall campaigns for the 2004 MCI G4500?: 16,711 units in 6 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the MCI G4500 have for all model years?: NHTSA lists 9 recall campaigns for the MCI G4500, model years 2000 to 2004. 6 of them name the 2004 model year.
Is an NHTSA investigation of the 2004 MCI G4500 open?: No. Each of the 3 investigations that name this model year has a closing date in the NHTSA file.