Loaded Bike Rack Obstructs Rear Lighting – 2019-2021 MCI D45CRTLE, J3500, & J4500 Coaches

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INSTRUCTION TO SERVICE
ITS: 60725
SECTION:
273 – Exterior Lights.
WRITTEN BY:
Scott Geier Technical Service Specialist.
ISSUE:
When bicycles are loaded onto the rear bike racks, can block the brake, and tell lights.
SUMMARY:
Install auxiliary rear brake and tell lights.
ITS- 60725
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
23V240
Not Applicable
INSTRUCTION TO SERVICE
ITS- 60725 Page 2 of 8
INSTRUCTION TO SERVICE
ITS- 60725 Page 3 of 8
PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Using light plates (Item # 1), and (Item #2), as a templates, drill ¼ inch dia. hole through the face of the bike rack frame tube. Ensure only first of the tube is drilled through. Secure plates to the frame using rivets (Item #5). See figure 1 for light bracket installation measurements.
Figure 1: Light brackets installation reference.
3. Install lights (Item #3) with grommets (Item #4) into the light plates. See figure 2.
Figure 2: Lights and grommets installaton reference.
INSTRUCTION TO SERVICE
ITS- 60725 Page 4 of 8
4. Route auxiliary lights rear bike harness (Item #7) from the streetside taillights to the curbside taillights along the existing engine compartment harnesses. See figure 3.
Figure 3: Auxiliary lights rear bike harness installation reference.
INSTRUCTION TO SERVICE
ITS- 60725 Page 5 of 8
5. From the auxiliary lights rear bike harness (Item #7), connect EC-P539, EC-P540, EC-P542, EC-P543 to engine compartment harness. Then connect EC-P539A, EC-P540A, EC-P542A, EC-P543A to the turn, tail, and stop lights. See figures 4.
Figure 4: Auxiliary lights rear bike harness streetside and curbside bus harness reference.
INSTRUCTION TO SERVICE
ITS- 60725 Page 6 of 8
6. Route auxiliary lights rear bike harness (Item #7) through the hole in the rear bumper, along the bike rack frame as shown in view “F”, section D-D, detail “H”, and section G-G.
7. Drill 17/64-inch dia. hole onto the right-side bottom tube assembly bracket and bumper beam. Mount bracket using clamps (Item #9) as a guide and as per section G-G. Secure auxiliary lights bike rack harness (Item #7) in place using clamps and secure using tapping screws (Item #10).
8. Drill 17/64-inch dia. hole onto the rear bike frame using clamps (Item #9) as a guide and as per section D-D, detail “E”. Secure harness using self-tapping screws (Item #10).
INSTRUCTION TO SERVICE
ITS- 60725 Page 7 of 8
9. Install connectors to the rear auxiliary lights on the bike rack. See figure 5.
Figure 5: Auxiliary lights rear bike harness connection to aux bike lights reference.
10. Install adhesive tie base onto interior side of the curbside bumper and fasten harness using tyraps (Item #11).
NOTE: Clean surface where tie base will be applied with isopropyl alcohol (Item #12 NF PN: 23-05-0005) and allow 60 seconds of flash-off before applying tie base.
11. Use tyraps (Item #11) as required to secure the harnesses. Coil up any extra length in the engine compartment.
12. Apply Sikaflex (Item #12) as required to seal holes in the rear bumper.
13. Turn the main battery disconnect switch to the “ON” position.
14. Start the bus and perform brake, turn, and tell light function test.
INSTRUCTION TO SERVICE
ITS- 60725 Page 8 of 8
LABOUR ESTIMATE
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
Install auxiliary rear brake and tell lights.
1
1.50
1.50
PARTS REQUIRED
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
1023667
PLATE-LIGHT L/R
2
EA
2
1023712
PLATE-LIGHT CENTER
1
EA
3
07-07-1932
LAMP – TAIL LIGHT, LED
6
EA
4
07-07-1941
GROMMET
6
EA
5
336379
RIVET-HUCKLOK 1/4″ .187-.437
12
EA
7
1024592
HRNS-AUX LTS REAR BIKE RACK
1
EA
8
19-04-0283
TIE BASE – ADH MT
1
EA
9
19-04-0451
CLAMP-LINE SUPPORT 9/16″I.D, SILICONE COVERED, ORA
5
EA
10
19-1-529
SCREW-TAPPING,THREAD ROLLING,DOG POINT
5
EA
11
19-11-258
TYRAP-7.31″ LONG,BLACK
26
EA
12
23-02-0016
SIKAFLEX – UV BLACK
0.010
OZ
13
23-05-0005
ALCOHOL – ISOPROPYL
0.010
OZ

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IMPORTANT SAFETY RECALL NOTICE
18-May-2023 VIA EMAIL AND US MAIL
Loop Trans, Inc.
615 Dado ST
San Jose, CA 95131
Subject: Motor Vehicle Safety Recall 23V240 – rear lighting with bicycle rack (loaded)
To Whom it May Concern:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Motor Coach Industries, Inc. (MCI) has decided that 2019-2021 MCI Model D45CRTLE, J3500 and J4500 coaches equipped with an optional rear mounted bicycle rack, MCI PN NS03-33-3736 or 951488 fail to conform to Federal Motor Vehicle Safety Standard No. 108; Lamps, reflective devices, and associated equipment. MCI has determined Loop Trans, Inc. is the Owner/Operator of the vehicles listed below which are affected by this recall action.
Make: MCI
Model Year VIN Model Year VIN
J 3500
2021
2MGKJMXAXMW021064
J 3500
2021
2MGKJMXA9MW021069
J 3500
2021
2MGKJMXA1MW021065
J 3500
2021
2MGKJMXA5MW021070
J 3500
2021
2MGKJMXA3MW021066
J 3500
2021
2MGKJMXA7MW021071
J 3500
2021
2MGKJMXA5MW021067
J 3500
2021
2MGKJMXA9MW021072
J 3500
2021
2MGKJMXA7MW021068
J 3500
2021
2MGKJMXA0MW021073
When bicycles are loaded onto the rack, the bicycles can obscure or reduce the lighting displayed rearward to traffic behind the coach.
Obscured lighting increases the risk of a crash.
An auxiliary lighting kit and labor required to accomplish the recall will be provided by MCI free of charge. MCI will install the lighting kit and ensure proper functionality. Please contact your TSM, RPSM or the MCI Customer Service Line at 1-800-241-2947 and arrange for the corrective action to be incorporated on your coach at your nearest MCI Service Center.
Alternatively, you can request parts and instructions necessary to conduct this retrofit and charge the time for actual labor back to MCI through the normal warranty process. MCI estimates the repair time to be approximately 4 hours, excluding vehicle and shop logistics.
The necessary parts and instructions required to conduct this corrective action are planned to be available in July 2023.
Until the corrective action can be incorporated on the above vehicles, MCI recommends against utilizing the bicycle rack.
Page 2 of 2
If you are a lessor of vehicles which are affected, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
If you have sold or otherwise transferred the vehicle(s) identified above, please contact the MCI Customer Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator of the vehicle(s).
If you had this corrective action performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall. Please contact your TSM (Technical Service Manager) or RPSM (Regional Product Support Manager) with details.
If MCI is unable to correct this defect within a reasonable time, you may submit a written complaint to the:
Administrator,
National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
Washington, DC, 20590,
Or call 1-888-327-4236 (TTY: 1-800-424-9153);
or go to http://www.safercar.gov.
We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees.
Thank you for your attention to this important matter.
Sincerely,
MOTOR COACH INDUSTRIES INC.
By: Jim Johnson
Vehicle Safety & Regulatory Compliance Manager
(256) 453-7181
[email protected]

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IMPORTANT SAFETY RECALL NOTICE
DATE VIA FIRST CLASS US MAIL
Loop Trans, Inc.
615 Dado ST
San Jose, CA 95131
Subject: Motor Vehicle Safety Recall 23V240 – rear lighting with bicycle rack (loaded)
To Whom it May Concern:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Motor Coach Industries, Inc. (MCI) has decided that 2019-2021 MCI Model D45CRTLE, J3500 and J4500 coaches equipped with an optional rear mounted bicycle rack, MCI PN NS03-33-3736 or 951488 fail to conform to Federal Motor Vehicle Safety Standard No. 108; Lamps, reflective devices, and associated equipment. MCI has determined Loop Trans, Inc. is the Owner/Operator of the vehicles listed below which are affected by this recall action.
Make: MCI
Model Year VIN Model Year VIN
J 3500
2021
2MGKJMXAXMW021064
J 3500
2021
2MGKJMXA9MW021069
J 3500
2021
2MGKJMXA1MW021065
J 3500
2021
2MGKJMXA5MW021070
J 3500
2021
2MGKJMXA3MW021066
J 3500
2021
2MGKJMXA7MW021071
J 3500
2021
2MGKJMXA5MW021067
J 3500
2021
2MGKJMXA9MW021072
J 3500
2021
2MGKJMXA7MW021068
J 3500
2021
2MGKJMXA0MW021073
When bicycles are loaded onto the rack, the bicycles can obscure or reduce the lighting displayed rearward to traffic behind the coach.
Obscured lighting increases the risk of a crash.
We are pleased to inform you the lighting kits are now available. We urge you to contact your TSM, RPSM or the MCI Customer Service Line at 1-800-241-2947 and arrange for the corrective action to be incorporated on your coach at your nearest MCI Service Center.
This auxiliary lighting kit and labor required to accomplish the recall will be provided by MCI free of charge. MCI will install the lighting kit and ensure proper functionality.
Alternatively, you can request parts and instructions necessary to conduct this retrofit and charge the time for actual labor back to MCI through the normal warranty process. MCI estimates the repair time to be approximately 1.5 hours, excluding vehicle and shop logistics.
Page 2 of 2
If you are a lessor of vehicles which are affected, it is required that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
If you have sold or otherwise transferred the vehicle(s) identified above, please contact the MCI Customer Service Line at 1-800-241-2947 with all of the information you have regarding the current owner/operator of the vehicle(s).
If you had this corrective action performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall. Please contact your TSM (Technical Service Manager) or RPSM (Regional Product Support Manager) with details.
If MCI is unable to correct this defect within a reasonable time, you may submit a written complaint to the:
Administrator,
National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
Washington, DC, 20590,
Or call 1-888-327-4236 (TTY: 1-800-424-9153);
or go to http://www.safercar.gov.
We regret any inconvenience which this action may cause you. However, we are concerned about the safety of your passengers and employees.
Thank you for your attention to this important matter.
Sincerely,
MOTOR COACH INDUSTRIES INC.
By: Jim Johnson
Vehicle Safety & Regulatory Compliance Manager
(256) 453-7181
[email protected]

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-240
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Motor Coach Industries APR 05, 2023 NHTSA Recall No. : 23V-240 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Motor Coach Industries Address : 200 East Oakton Street
Des Plaines IL 60018
Company phone : 1-800-241-2947
Population :
Number of potentially involved : 140 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2019-2021 Motor Coach Industries D45CRTLE, J3500, J4500 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Recall population was determined based on coaches that received an optional rear mounted bike rack. Coaches without an optional bike rack are not affected.
Production Dates : AUG 01, 2019 – MAY 31, 2022 VIN Range 1 : Begin : 1M8ZDMBA9KP081004 End : 1M8ZDMNAXMP081141 ✔ Not sequential Description of Noncompliance :
Description of the Noncompliance :
On coaches with rear mounted bike racks, inward lighting angles required by FMVSS 108. FMVSS 1 : 108 – Lamps, reflective devices, and assoc. Equipment FMVSS 2 : NR
Description of the Safety Risk : Rear illumination and visibility for approaching traffic may be reduced with bikes installed on the rack. Reduced visibility may increase the likelihood of a crash.
Description of the Cause : With bikes installed on the bike rack, the bike frame/seat/etc. block the inward angle illumination requirements of FMVSS 108. Identification of Any Warning
that can Occur : No known pre-warning.
Involved Components : Part 573 Safety Recall Report 23V-240 Page 2 Component Name 1 : INSTL-SWINGLOCK BIKE RACK
Component Description : Bike rack, rear mount, 5 position Component Part Number : 951488 Supplier Identification : Component Manufacturer
Name : Motor Coach Industries Address : NR
Des Plaines Illinois
Country : United States Chronology :
-Late 2022, MCI receives a request from a customer to install a 5-position bike rack on the rear of the coach
-February 2023, as design releases occur, it was noted there was a missing validation report for FMVSS 108 with the bike rack installed.
-Early-March 2023 MCI arranges for an outside test facility to check lighting with the rack installed to FMVSS 108.
-Mid-March 2023 – testing indicated likely non-compliance when bikes are mounted on the rack, where the inward angle lighting was impacted, in noncompliance with 108 6.1.3 Mounting location,
—6.1.3.1, “…complies with all photometric requirements…with all obstructions considered.”
-March 24, 2023 – analysis continues on the lighting angle candela readings via coach CAD models
-March 27, 2023 – engineering determined the bikes, as mounted, are deemed “obstructions” and would affect the inboard angle requirements.
-March 31, 2023 – issue was raised to the Vehicle Safety Committee where a recall determination was made Description of Remedy :
Description of Remedy Program : Motor Coach Industries (MCI) will provide instructions and a kit to add
lighting to the bike rack to ensure compliance when bikes are loaded to the rack. How Remedy Component Differs from Recalled Component : MCI will perform the installation of the kit for customers. If customers perform the installation, MCI will reimburse through our normal Warranty process.
The additional lights will be noticeable on the racks – currently no racks are equipped with ancillary lights. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-240
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
Current production will have the lighting kit installed prior to delivery to customers. Recall Schedule :
Description of Recall Schedule : MCI plans to issue recall letters in May 2023 once the final kit is validated
and material is available.
Planned Dealer Notification Date : MAY 01, 2023 – MAY 31, 2023
Planned Owner Notification Date : MAY 01, 2023 – MAY 31, 2023
* NR – Not Reported

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