- The problem
- 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."
- The risk
- The incorrect window glazing material may reduce the driver's visibility, increasing the risk of a crash.
- The fix
- 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.
Vehicle safety record
2002 Mci D4500 Problems, complaints & recalls
Owners have filed 1 complaint about the 2002 Mci D4500 with NHTSA, most often about the brakes (1). It is covered by 7 recalls, the latest in December 2025 for the door. For comparison, the 2001 has 0 and the 2003 has 0.
NHTSA data checked
CAbout as many problems as a typical D4500 year, for its age
#439 most complained-about 2002 vehicle
- Complaints
- 1
- Recalls
- 7
- Crashes
- 0
- Fires
- 0
- Injuries
- 0
- Deaths
- 0
Most common 2002 Mci D4500 problems
Share of all 1 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.
2002 Mci D4500 recalls 7
Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do
- The problem
- 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.
- The risk
- Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
- The fix
- 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.
- The problem
- Mci is recalling certain model year 2000-2009 d4000, model year 2001-2010 d4500 and model year 2005-2007 d4505 coaches equipped with ricon wheelchair lift (wcl) and a cassette-type wcl compartment door. The wheelchair lift may become disengaged from a locked position and slide unrestrained on its rollers in the storage structure, potentially breaking through the cassette door and extending beyond the outside of the door when the coach is in motion, particularly when the coach is making a left turn.
- The risk
- If the coach is in motion, potential injury to persons and/or damage to other vehicles or property could occur.
- The fix
- Mci will provide parts and labor to install free of charge to customers, a ricon designed retrofit kit that includes a spring loaded lock mechanism. The safety recall began on march 31, 2010. Owners may contact mci customer service line at 1-800-241-2947.
- The problem
- Mci is recalling certain model year 2002-2009 d series coaches, equipped with luminator horizon led side destination signs. The connector board can corrode due to an accumulation of moisture under the connector.
- The risk
- A short could occur, possibly causing smoke and fire.
- The fix
- Mci will notify owners and luminator will repair the buses free of charge. Please see luminator's defect report 09e-054. The safety recall began on november 9, 2009. Owners may contact luminator at 1-972-516-3033 or mci customer service at 1-800-241-2947.
- The problem
- On certain motor coaches, the boost connector housing can fail over time, exposing the positive and negative terminals.
- The risk
- This could result in the grounding of an unprotected circuit and could lead to a thermal event if not corrected.
- The fix
- 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.
- The problem
- On certain motor coaches equipped with detroit diesel series 60 engines, the turbocharger compressors can fail.
- The risk
- A FIRE CAN RESULT SHOULD THE TURBOCHARGER FAIL.
- The fix
- 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.
- The problem
- On certain motor coaches that have multiplex systems, when the coach's defroster motor is activated, certain high speed cell net controllers (hcnc) may lock up.
- The risk
- As a consequence of this lock up, the functions and systems that are part of the multiplex system will remain at their status immediately prior to the lockup. This could affect the electrical operation of brake lights, turn signals, ignition, instrumentation, etc.
- The fix
- Owners will be provided with defroster motor relays equipped with suppression resistors and installation instructions. Dealers will also replace the hcnc modules with upgraded modules. Owner notification is expected to begin during april 2002. 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 1-800-241-2947.
What owners say
Be the first D4500 owner to share.
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1 complaints about the 2002 Mci D4500
Newest first, as filed with NHTSA by owners.
Defective air brake equipment on mci d4500 buses.*Mr if there is less than 90 pci in the air system there is an audible buzzer and the hazard light illuminates indicating low air. The emergency brake system does not work until the air pressure is almost "0" on the manometer on the dashboard. *Bf *nm
Mci D4500: every year compared
All D4500 yearsQuestions about the 2002 Mci D4500
Does the 2002 Mci D4500 have any recalls?
Yes - NHTSA lists 7 recalls for the 2002 Mci D4500: door (December 2025); electrical system (October 2013); equipment adaptive / mobility (March 2010); interior lighting (November 2009) and more. Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.
What are the most common problems with the 2002 Mci D4500?
By the complaints owners filed with NHTSA, the most common problem areas are the brakes (1).
How many complaints has the 2002 Mci D4500 had?
1 complaints have been filed with NHTSA, the first on April 12, 2005 and the latest on April 12, 2005. Of these, 0 describe a crash and 0 a fire, and together they report 0 injuries and 0 deaths.
Is the 2002 Mci D4500 a reliable vehicle?
Its Safety Index is 48 out of 100 (grade C: about as many problems as a typical Mci D4500 year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.
Which Mci D4500 years have the most complaints?
2002 (1), 2004 (1). See every Mci D4500 year compared.
What should I do if my 2002 Mci D4500 has a problem?
If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data