Recall 18V309 covers 1,123 2011-2016 Mci D4000, D4500, D4005, D4505, and D4000ISTV coaches for exhaust bellow pipe holes. Free repair at any franchised Mci dealer.
Mci is recalling 1,123 2011-2016 D4000, D4500, D4005, D4505, and D4000ISTV motor coaches equipped with ISX engines because vibration can open holes in the exhaust bellow pipes. If a pipe opens during a regeneration cycle, hot exhaust gases can leak and raise the risk of a fire; Mci dealers will complete the repair free of charge.
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What's wrong?
The exhaust bellow pipe on 2011-2016 Mci D4000, D4500, D4005, D4505, and D4000ISTV motor coaches is part of the exhaust pipe assembly for coaches with Cummins ISX engines. The bellows section is a flexible metal joint that absorbs engine movement and heat expansion while carrying exhaust away from the engine and through the exhaust system.
On included coaches, the 08-20-1786 exhaust pipe assembly lets the bellows vibrate under some operating conditions. That vibration shortens the life of the metal bellows until a hole forms or the pipe fails. The updated assembly uses a shorter bellows with mesh over it to reduce premature metal fatigue.
An operator can receive an engine code when the exhaust leak is significant or when the pipe has failed. The insulation blanket around the bellows can also show soot or other damage, which is a warning sign to have the exhaust pipe inspected.
Who's affected?
Five coach models are included across the 2011-2016 model years, with exhaust-system and manifold/header/muffler/tail pipe component labels.
| 2016 Mci D4000 | Manifold/header/muffler/tail pipe |
|---|---|
| 2016 Mci D4000 | Exhaust system |
| 2016 Mci D4500 | Manifold/header/muffler/tail pipe |
| 2016 Mci D4500 | Exhaust system |
| 2016 Mci D4005 | Manifold/header/muffler/tail pipe |
| 2016 Mci D4005 | Exhaust system |
| 2015 Mci D4000 | Manifold/header/muffler/tail pipe |
| 2015 Mci D4000 | Exhaust system |
| 2015 Mci D4505 | Manifold/header/muffler/tail pipe |
| 2015 Mci D4505 | Exhaust system |
| 2015 Mci D4005 | Manifold/header/muffler/tail pipe |
| 2015 Mci D4005 | Exhaust system |
| 2015 Mci D4000ISTV | Manifold/header/muffler/tail pipe |
| 2015 Mci D4000ISTV | Exhaust system |
| 2014 Mci D4505 | Manifold/header/muffler/tail pipe |
| 2014 Mci D4505 | Exhaust system |
| 2014 Mci D4000ISTV | Manifold/header/muffler/tail pipe |
| 2014 Mci D4000ISTV | Exhaust system |
| 2014 Mci D4005 | Manifold/header/muffler/tail pipe |
| 2014 Mci D4005 | Exhaust system |
| 2014 Mci D4000 | Manifold/header/muffler/tail pipe |
| 2014 Mci D4000 | Exhaust system |
| 2013 Mci D4505 | Manifold/header/muffler/tail pipe |
| 2013 Mci D4505 | Exhaust system |
| 2013 Mci D4500 | Manifold/header/muffler/tail pipe |
| 2013 Mci D4500 | Exhaust system |
| 2013 Mci D4005 | Manifold/header/muffler/tail pipe |
| 2013 Mci D4005 | Exhaust system |
| 2013 Mci D4000ISTV | Manifold/header/muffler/tail pipe |
| 2013 Mci D4000ISTV | Exhaust system |
| 2013 Mci D4000 | Manifold/header/muffler/tail pipe |
| 2013 Mci D4000 | Exhaust system |
| 2012 Mci D4005 | Manifold/header/muffler/tail pipe |
| 2012 Mci D4005 | Exhaust system |
| 2012 Mci D4000ISTV | Manifold/header/muffler/tail pipe |
| 2012 Mci D4000ISTV | Exhaust system |
| 2012 Mci D4500 | Manifold/header/muffler/tail pipe |
| 2012 Mci D4500 | Exhaust system |
| 2012 Mci D4505 | Manifold/header/muffler/tail pipe |
| 2012 Mci D4505 | Exhaust system |
| 2011 Mci D4505 | Manifold/header/muffler/tail pipe |
| 2011 Mci D4505 | Exhaust system |
| 2011 Mci D4500 | Manifold/header/muffler/tail pipe |
| 2011 Mci D4500 | Exhaust system |
| 2015 Mci D4500 | Manifold/header/muffler/tail pipe |
| 2015 Mci D4500 | Exhaust system |
| 2014 Mci D4500 | Manifold/header/muffler/tail pipe |
| 2014 Mci D4500 | Exhaust system |
| 2012 Mci D4000 | Manifold/header/muffler/tail pipe |
| 2012 Mci D4000 | Exhaust system |
| Units affected | 1,123 |
A matching year and model does not confirm inclusion. Check your VIN to confirm whether this recall applies to your specific bus.
What's the safety risk?
If the exhaust pipe develops a hole, hot exhaust gases can escape during regeneration and increase the risk of a fire. Treat an engine code, soot, or damaged bellows insulation as a reason to schedule service promptly and avoid hard use until inspected. Repair is free at any franchised Mci dealer.
What should I do?
- Check your VIN to confirm your 2011-2016 Mci D4000, D4500, D4005, D4505, or D4000ISTV coach is included in this recall.
- Contact a franchised Mci dealer to schedule the free bellows pipe assembly replacement for exhaust bellow pipes that develop holes from vibration.
- Mention recall number 18V309 when you call, and ask whether the improved part is in stock.
- Bring the recall notice to the dealer if Mci mailed one, or bring the VIN and recall number instead.
- Avoid unnecessary operation until the dealer completes the exhaust repair.
What happens at the repair
At the dealer, an Mci technician replaces the exhaust bellows pipe assembly with an improved part. The recall repair is free, including parts and labor. Mci has a general reimbursement plan on file for documented out-of-pocket repairs tied to this recall. Bring prior repair paperwork to the service desk, or contact Mci customer service at 1-800-241-2947 to ask how to submit the claim.
| Reimbursement | Reimbursement available |
|---|
Timeline
| May 13, 2018 | NHTSA published the recall |
|---|---|
| July 10, 2018 | Dealer notification began |
| July 10, 2018 | Dealer notification ended |
| July 10, 2018 | Owner notification mailed |
| July 10, 2018 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 18V309?
Recall 18V309 covers 1,123 2011-2016 Mci D4000, D4500, D4005, D4505, and D4000ISTV motor coaches with ISX engines. Exhaust bellows pipes can develop holes from vibration, allowing hot exhaust gases to leak during regeneration and increasing fire risk. Mci dealers replace the bellows pipe assembly for free.
What should I do if my 2011-2016 Mci D4000, D4500, D4005, D4505, or D4000ISTV is on this recall?
Check your VIN to confirm your specific coach is included in recall 18V309. If it is, contact a franchised Mci dealer to schedule replacement of the bellows pipe assembly with the improved part. Reference recall number 18V309 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to repair safety defects at no cost, and Mci will replace the bellows pipe assembly with an improved part free of charge at a franchised Mci dealer.
What is the safety risk for recall 18V309?
The safety risk is fire. If vibration creates a hole in the exhaust bellows pipe, hot exhaust gases can leak during a regeneration cycle. Confirm your VIN, then ask a franchised Mci dealer or Mci customer service at 1-800-241-2947 for operating guidance until the free repair is complete.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/18V309000 |
|---|---|
| Mci customer service | 1-800-241-2947 |
| NHTSA recall # | 18V309 |
| NHTSA recall # (full) | 18V309000 |
Source documents
-
Download Recall Investigation Document (PDF) (PDF) - Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 25, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →