2003 MCI G4500 Recalls (8)

Campaign:
03V411000 on 10/27/2003
Component:
Suspension
Manufactured:
12/31/1999 - 03/30/2003
Affected:
428
Defect:
On certain motor coaches equipped with tag axle swing arm assemblies, insufficient weld metal and/or weld penetration on the tag axle swing arm where it meets the pivot spindle tube could lead to stress and fatigue cracks.
Consequence:
This could result in complete separation of the tag axle from the coach, increasing the risk of a crash.
Correction:
Mci will inspect and repair or replace the assemblies. the recall began on october 20, 2003. 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 1-800-321-2947.
Notes:
Customers can also contact the national highway traffic safety administration's auto safety hotline at 1-888-dash-2-dot (1-888-327-4236).
Campaign:
04V329000 on 07/07/2004
Component:
Suspension:front
Affected:
518
Defect:
On certain motor coaches, the front lower radius rod mounting bracket components may not have been welded sufficiently.
Consequence:
These welds may crack, allowing movement and potential separation of the radius rod mounting bracket, which could result in a crash.
Correction:
Owners have been provided with repair instructions. the recall began on july 1, 2004. owners should contact mci at 1-800-241-2947.
Notes:
Mci recall no. 227.customers can also contact the national highway traffic safety administration auto safety hotline at 1-888-dash-2 dot (1-888-327-4236).
Campaign:
06V140000 on 04/26/2006
Component:
Engine and engine cooling:engine:diesel
Manufactured:
12/31/2000 - 12/30/2004
Affected:
4,765
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.
Correction:
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.
Notes:
Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
Campaign:
06V458000 on 11/29/2006
Component:
Suspension:rear:axle:non-powered axle assembly
Manufactured:
12/31/1999 - 03/30/2003
Affected:
518
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.
Correction:
Please note that this campaign has been superseded by 08v121.
Notes:
Customers can also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
Campaign:
07V096000 on 03/12/2007
Component:
Steering:gear box (other than rack and pinion)
Manufactured:
12/31/1999 - 03/30/2004
Affected:
518
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.
Correction:
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.
Notes:
Customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.
Campaign:
08V121000 on 03/17/2008
Component:
Suspension:rear:axle:non-powered axle assembly
Manufactured:
12/31/1999 - 03/30/2004
Affected:
542
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.
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.
Correction:
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.
Notes:
Customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov.
Campaign:
09V345000 on 09/01/2009
Component:
Structure:body:door
Manufactured:
05/31/2001 - 10/30/2004
Affected:
352
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.
Correction:
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.
Notes:
Owners may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to <a href=http://www.safercar.gov>http://www.safercar.gov</a> .
Campaign:
13V498000 on 10/30/2013
Component:
Electrical system
Affected:
10,016
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 to heat.
Consequence:
Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
Correction:
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.
Notes:
Owners may also contact the national highway traffic safety administration vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to www.safercar.gov.

2003 MCI G4500 TSBs (4)

Bulletin:
SB-3042
Component:
355200 equipment:other:owners/service/other manual
Summary:
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 mo
Bulletin:
SB-3037
Component:
161100 structure: frame and members:underbody shields
Summary:
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
Bulletin:
354
Component:
102000 power train:manual transmission
Summary:
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
Bulletin:
SB-357
Component:
980000 unknown or other
Summary:
Motor coach indudstries: information on replacing the coolant pump that may have a problem. *rm

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