The Recall Desk
Our severity:SevereNHTSA·25V567000·Announced 2025-08-29

MCI Recalls Electric Buses Due to Battery Overheating and Fire Risk

Motor Coach Industries is recalling specific 2020-2025 electric buses because an inadequate weld and software error may cause battery overheating and fire.

What this means for you

Our assessment, not the agency’s: severity 4/5 (Severe).

The hazard poses a serious risk of illness, injury, or structural failure. Stop using the product immediately and contact the manufacturer for a refund or repair.

Our severity reasoning: The recall involves a structural vehicle defect (inadequate weld) that creates a significant risk of fire, meeting the criteria for a Severe rating.

Plain-English summary

Motor Coach Industries (MCI) is recalling certain 2020-2021 J4500E, 2021 D45CRTELE, 2023 J4500E, 2023-2024 D45CRTELE, 2024 D45CRTE, and 2025 J4500E buses. The recall involves 59 vehicles affected by an inadequate weld on the high voltage battery busbar and incorrect software.

These defects may cause the battery module to overheat, which increases the risk of a fire. No specific injuries or fatalities are reported in the source text.

MCI will inspect and replace the battery module as necessary and update the BMS software. Owner notification letters were mailed on October 6, 2025. Owners may contact MCI customer service at 1-800-241-2947.

The recalled product

Product
MCI D45CRTELE, J4500E, D45CRTE
Brand
MCI
Manufacturer
Motor Coach Industries
Category
Vehicle — Electric Bus
Hazard
Affected units
59

Is your product affected?

Check your packaging against the codes below. If any of them match, the product is part of this recall.

Model numbers (3)

  • D45CRTELE
  • J4500E
  • D45CRTE

Distribution

Distributed nationwide across the United States.

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