Year · Make · Model

2004 NEW Flyer D40I

What the National Highway Traffic Safety Administration knows about this vehicle: every recall, every consumer complaint, every defect investigation, every NCAP crash test. Sourced directly from NHTSA data feeds.

Open recalls

NHTSA complaints

Defect investigations

Service bulletins

Recalls

4 campaigns

13V485000·ELECTRICAL SYSTEM2013-09-20

New Flyer is recalling certain model year 2004-2006 D40I transit buses manufactured January 14, 2005, through October 19, 2006, and equipped with Sure Power battery equalizers and DC-DC converters 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.

RiskOnce electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

FixNew Flyer will notify owners, and dealers will replace the equalizers and converters, free of charge. The recall began on November 4, 2013. Owners may contact New Flyer at 1-204-982-8400. New Flyer's recall number is R13-021.

09V367000·INTERIOR LIGHTING2009-09-24

NEW FLYER IS RECALLING CERTAIN MODEL YEAR 2002 THROUGH 2009 TRANSIT BUSES MANUFACTURED BETWEEN MAY 2002 AND SEPTEMBER 2009 EQUIPPED WITH LUMINATOR HORIZON LED SIDE DESTINATION SIGNS. THE CONNECTOR BOARD CAN CORRODE DUE TO AN ACCUMULATION OF MOISTURE UNDER THE CONNECTOR.

RiskA SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.

FixNEW FLYER WILL NOTIFY OWNERS AND REPAIR THE BUSES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER2, 2009. OWNERS MAY CONTACT NEW FLYER CUSTOMER SERVICES AT 1-204-934-4876.

06V015000·SERVICE BRAKES, AIR:SUPPLY:CHECK VALVE2006-01-18

ON CERTAIN TRANSIT BUSES EQUIPPED WITH RELAY VALVES BUILT BY HALDEX/MIDLAND AND DISTRIBUTED BY MERITOR/WABCO WITH VALVE BODY DATE CODE OF 342A4K. THIS VALVE, WHICH IS INSTALLED IN THE REAR AXLE AIR BRAKE CIRCUIT, CAN FAIL RESULTING IN A LOSS OF AIR PRESSURE TO THE REAR SERVICE BRAKES.

RiskFAILURE OF THE VALVE WOULD DISABLE THE REAR AXLE SERVICE BRAKE CIRCUIT AND RESULT IN EXTENDED STOPPING DISTANCES WHICH COULD RESULT IN A CRASH.

FixDEALERS WILL INSPECT TO SEE IF THE INSTALLED RELAY VALVE HAS A DATE CODE OF 342A4K AND IF NECESSARY WILL REPLACE THE VALVE FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 25, 2006. OWNERS MAY CONTACT NEW FLYER AT 204-934-4803.

05V370000·ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN2005-08-25

ON CERTAIN TRANSIT BUSES, HYDRAULIC FLUID CAN LEAK AT THE FLANGE FITTING DUE TO IMPROPER INSTALLATION PROCEDURES. INCORRECT INSTALLATION PROCEDURES MAY CAUSE DAMAGE TO THE O-RING OF THE FLANGE ASSEMBLY, COMPROMISING THE SEALING CAPABILITY OF THE O-RING.

RiskLEAKS CAUSED DUE TO DAMAGED O-RINGS COULD CAUSE HYDRAULIC FLUID TO BE SPRAYED ONTO HOT SURFACES AND IGNITE.

FixNEW FLYER WILL CONTACT CUSTOMERS WITH PARTS AND INSTRUCTIONS ON HOW TO COMPLETE THIS RECALL. THE RECALL BEGAN ON AUGUST 30, 2005. OWNERS MAY CONTACT NEW FLYER AT 204-934-4874.

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