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Recall data is sourced from official U.S. government agencies (CPSC, FDA, NHTSA, USDA) and processed using AI to improve readability. This site is not affiliated with or endorsed by any government agency. Always refer to the original agency notice for authoritative information.

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Medium RiskNHTSA
Vehicles/Commercial Vehicles

2020-2025 MCI J4500E and D45CRTELE Buses Recalled for Battery Fire Risk

Agency Publication Date: August 29, 2025
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Summary

Motor Coach Industries (MCI) is recalling approximately 59 electric buses across several models from 2020 to 2025. The recall involves specific J4500E, D45CRTELE, and D45CRTE buses where an inadequate weld on the high voltage battery busbar, combined with incorrect software, can cause the battery module to overheat. MCI will provide a free inspection, replace the battery module if a weld defect is found, and update the Battery Management System (BMS) software.

Risk

A battery module that overheats poses a significant risk of a vehicle fire. The defect involves a hardware weld failure on the busbar and a software error that fails to mitigate overheating conditions.

What You Should Do

  1. This recall affects certain Motor Coach Industries (MCI) buses, including the 2020-2021, 2023, and 2025 J4500E; the 2021 and 2023-2024 D45CRTELE; and the 2024 D45CRTE.
  2. Contact Motor Coach Industries customer service at 1-800-241-2947 to schedule a free inspection and repair for your vehicle.
  3. The authorized service center will inspect the battery module, replace it if necessary, and perform a software update on the Battery Management System (BMS).
  4. For further information or questions regarding this safety recall, call the NHTSA Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153) or visit www.nhtsa.gov/recalls.

Your Remedy Options

You have 2 options:

๐Ÿ”งOption 1: Free Repair

Inspection and software update.

How to: MCI will inspect and replace the battery module as necessary. MCI will also update the BMS software.
๐Ÿ”„Option 2: Free Replacement

Battery module replacement if necessary.

How to: MCI will inspect and replace the battery module as necessary.

Affected Products

Product: 2020-2025 MCI J4500E
Part / Model:
J4500E

Affected model years: 2020, 2021, 2023, 2025.

Product: 2021-2024 MCI D45CRTELE
Part / Model:
D45CRTELE

Affected model years: 2021, 2023, 2024.

Product: 2024 MCI D45CRTE
Part / Model:
D45CRTE

Affected model years: 2024.

Additional Information

Agency: National Highway Traffic Safety Administration (NHTSA)
Recall ID: 25V567000
Status: Active
Manufacturer: Motor Coach Industries
Sold By: Authorized Motor Coach Industries dealers
Units Affected: 59 vehicles(2% estimated defective)
Park Vehicle: No
Park Outside: No
OTA Update: No
Product Type: Vehicle (V)
Recall Classification: Safety Defect
Owner Notification Date: October 6, 2025
Distributed To: Nationwide
Agency Last Updated: October 10, 2025

Were You Affected by This Recall?

If you or a family member were harmed by this recalled product, you may have legal rights. Consider consulting a consumer protection attorney to understand your options for compensation.

Find an Attorney

This is general information, not legal advice. Go Backs is not a law firm and does not provide legal services.

AI-Enhanced Content: The summary, action steps, and risk assessment on this page were generated by AI from official government recall data to improve readability. This is not legal or medical advice. Always refer to the official agency sources below for authoritative information.

Sources: NHTSA Notice ยท Raw API Response