New Flyer C40LF Recalls & Complaints by Model Year
NHTSA lists 27 safety recalls and 1 owner complaint across 18 model years of the New Flyer C40LF (1996–2013). The most-complained-about year is 1997.
Pick your New Flyer C40LF model year
What New Flyer C40LF owners complain about
Across all model years, owners have filed 1 complaint with NHTSA. The 1997 model year has the most, with 1.
All New Flyer C40LF recalls (27)
Every NHTSA safety campaign that lists a New Flyer C40LF, most recent first, with the model years each one covers.
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Suspension: front
New Flyer Industries Ltd (New Flyer) is recalling certain 2006 L40LFand DE60LF transit buses, 2006-2007 C35LF, C40LFR, D35LF, D40LFR, D60LFR, DE40LF and DE40LFR transit buses, and 2005-2007 C40LF, D40LF, D60LF, DE60LFA, GE40LF, 2007 D35LFR, and DE60LFR transit buses. These vehicles are equipped with MAN V8-65L axle beams that may have…
Remedy: New Flyer will notify owners, and dealers will inspect the axle beams and determine a repair, as necessary, free of charge. The recall began on March 10, 2017. Owners may contact New Flyer customer service at…
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Seats
New Flyer Industries, Ltd. (New Flyer) is recalling certain model year 2015 New Flyer MD30, 2012 C35LFR, 2010-2011 D35LFR, NABI 35LFW, 2011 D40LFR, 2010-2012 D60LFR and NABI 31LFW, 2010 C40LF, DE35LF, D40LF, DE40LFA, DE60LFA, GE35LFR and GE40LF, 2009 DE60LF and GE40LFR, 2010-2013 C40LFR, DE60LFR, NABI 416 and NABI 60BRT, 2010-2015 XD35,…
Remedy: New Flyer will notify owners instructing them to inspect their seats for missing welds. Recaro will supply replacement anchorage brackets and cover the labor to replace them if any welds are missing, free of charge.…
Model years: 2010
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Engine (engine and engine cooling)
New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2009-2012 C35LFR, 2008-2013 C40LF, 2008-2013 C40LFR, 2009 L40LFR, 2009 C35LF, 2013-2014 XN35, 2011-2014 XN40, and 2012-2014 XN60 buses, equipped with certain Cummins Westport ISL G engines. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent…
Remedy: Cummins will notify owners on behalf of New Flyer, and Cummins service centers will administer the repairs which include securing the ends of the 90-degree elbow and reprogramming the electronic control module (ECM)…
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Engine (engine and engine cooling)
New Flyer Industries Canada ULC (New Flyer) is recalling certain model year 2009 C35LF and L40LFR, model year 2009-2012 C35LFR, model year 2008-2013 C40LF and C40LFR, model year 2013 XN35, model year 2011-2013 XN40 and model year 2012-2013 XN60 transit buses equipped with certain Cummins Westport Model ISL G engines. In the affected…
Remedy: New Flyer will notify owners, and authorized Cummins Inc. and Cummins Wesport Inc. facilities will upload a new ECM calibration, free of charge. The recall began on March 21, 2014. Customers may contact New Flyer at…
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Parking brake
New Flyer is recalling certain model year 2010-2012 transit buses, models C40LF, C40LFR, D35LFR, D40LFR, D60LFR, XD35, XD40, XDE35, XDE40, and XN40. Air pressure may leak from the parking brake chambers causing the parking brakes to drag while the vehicle is driven.
Remedy: New Flyer will notify the owners and the affected brake chambers will be replaced, free of charge. The recall began on November 13, 2012. Owners may contact New Flyer at 1-204-224-6706 for more information.
Model years: 2011
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Turbo/supercharger (engine and engine cooling)
New Flyer is recalling certain model year 2005-2006 C40LF and 2006 C40LFR transit buses, equipped with John Deere 8.1 liter turbocharged, compressed natural gas engines, model number 6081HFN04, manufactured from June 2002 through January 2008. Failures can occur within the engine turbocharger. The turbine or compressor wheel may fail,…
Remedy: The remedy for this issue is still under development. An interim letter was mailed on October 3, 2012. Owners may contact New Flyer at 1-204-224-1251.
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Latch (latches/locks/linkages)
New flyer is recalling certain model year 2007-2011 low floor transit buses produced from may 24, 2007, through march 1, 2011 and equipped with teeter lever assemblies. There is insufficient engagement between the teeter lever base and the cam plate.
Remedy: New flyer is working with the manufacturer of the teeter lever assemblies, vapor bus, to repair the affected buses free of charge. Please see vapor bus defect report 11e-010. The safety recall began on april 29, 2011.…
Model years: 2008
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Interior lighting
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.
Remedy: New 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.
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Service brakes, air
New flyer is recalling 319 my 2008 c40lf, c40lfr, d35lf, d40lf, d41lf, d61lfr, de41lf, de61lf, e40lfr, ge40lfr, and de41lfr transit buses equipped with parker hannifin (vansco) control modules. A certain batch of the programmable logic control modules may have a manufacturing defect. This defect could produce erratic behavior of certain…
Remedy: The affected modules will be replaced free of charge. The recall began on july 14, 2008. Owners may contact new flyer at 1-204-982-8400.
Model years: 2008
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Steering
On certain transit buses, the u-joint assemblies have inadequate spline engagement on one of the two end yokes.
Remedy: The u-joint assembly will be inspected and replaced if necessary. The recall began on june 10, 2007. Owners may contact new flyer at 1-204-934-4874.
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Exterior lighting
Certain transit buses fail to comply with the requirements of federal motor vehicle safety standard no. 108, "lamps reflective devices, and associated equipment." the flashing deceleration lamps were an optional item for some of these buses.
Remedy: Dealers will rewire the electrical system to remove the flashing function or install a new programmable logic controller (plc) which will make the lamps burn steady free of charge. The recall began on march 5, 2007.…
Model years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
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Equipment adaptive/mobility
On certain transit buses, the spot welds which hold the wheelchair ramp hinge assembly together can fail allowing the ramp to separate, when deployed under load, from the bus frame.
Remedy: Dealers will add new hardware to the hinges which will make the spot-welding redundant. The recall began on february 15, 2006. Owners may contact new flyer at 1-204-934-4874.
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Check valve (service brakes)
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.
Remedy: Dealers 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…
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Fan (engine and engine cooling)
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.
Remedy: New 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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Tie rod assembly (steering)
On certain transit buses equipped with meritor front axle assemblies, a weld is missing on the radius rod attachment bracketand the bracket may fatigue and fail while in use.
Remedy: Dealers will replace the brackets free of charge. The recall began on april 6, 2005. Owners may contact new flyer at 204-934-4874.
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Turbo/supercharger (engine and engine cooling)
On certain transit buses manufactured with detroit diesel series 50 engines, the turbocharger compressor wheel can break, resulting in shaft imbalance and lubricating oil passes into the exhaust system.
Remedy: Detroit diesel is conducting the owner notification and remedy for this campaign. Dealers will install an exhaust temperature sensor and reprogram the emc calibration free of charge. Owners may contact detroit diesel…
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Diesel (engine and engine cooling)
On certain transit buses equipped with cummins westport b gas plus or c gas plus 6 cylinder engines, the electronic control module calibration may not correctly detect a throttle plate actuator failure that could result in an uncommanded open throttle condition.
Remedy: Dealers will replace the electronic control module calibration free of charge. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a…
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Wheels
On certain low floor transit buses, the custom wheel paint thickness was out of specification and the wheel paint type changes from a glass state to a rubber state around the brake temperatures.
Remedy: New flyer dealers will replace the wheels, wheel studs, and modify the front air brake circuit to reduce the rear wheel brake temperature. Owner notification began june 30, 2002. Owners who take their vehicles to an…
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Hose, piping, and connections (steering)
On certain low floor buses, the power steering hose was incorrectly installed.
Remedy: Dealers will replace the hose. Owner notification began july 1, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time…
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Vehicle speed control
On certain buses equipped with electronic throttle control/accelerator pedals supplied by williams controls industries, the weld attaching the clevis to the plate has insufficient penetration and could allow the clevis to separate from the plate.
Remedy: Williams controls is handling the replacement of this pedal. Owners who do not receive the free remedy within a reasonable time should contact williams control at 1-503-684-8600 or new flyer at 204-982-8181.
Model years: 2001
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Door (structure)
On certain low floor transit buses equipped with adhesively bonded aluminum bus door panels, due to an imperfect bonding of the door panel skin to the panel frame, environmental moisture may infiltrate regions of imperfect bonding and cause separation of the frame and door panel.
Remedy: Vapor will notify customers to have their buses inspected and will install mechanical fasteners to attach the skins to the frame elements free of charge. Owner notification began december 10, 2001. Owners who take…
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Tie rod assembly (steering)
Vehicle description: transit buses. The clamp nuts for the center link tie rods may have been inadequately tightened.
Remedy: New flyer will will inspect the tie rod end clamp lock nuts to ensure that the nuts are properly tightened. Any damaged tie rods will be replaced. Owner notification began september 17, 2001. Owners who take their…
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Suspension
Vehicle description: transit buses. There could be a casting defect in the left side spring tower. The spring towers support the vehicle structure, and failure of a tower could cause a sudden shift in the front axle.
Remedy: Dealers will replace the spring tower. Owner notification is expected to begin during may 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy…
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12v/24v/48v battery (electrical system)
Vehicle description: transit buses equipped with vanner 60 series battery equalizers. The equalizer could fail to operate properly and cause malfunction of the battery charging system.
Remedy: Dealers will inspect the buses for certain equalizers by the date code. The affected equalizers will be replaced by vanner. New flyer is conducting the owner notification for this campaign. Owners who take their…
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Service brakes, air
Vehicle description: certain transit buses equipped with ABS fail to comply with the requirements of FMVSS no. 121, "air brake systems." the rear brake release time can exceed the requirements.
Remedy: The repair will involve installing a quick release valve or increasing the size of the rear brake control line.
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Springs/bags (suspension)
Vehicle description: transit buses. The front axle's spring tower bolts may not have been adequately tightened.
Remedy: Dealers will reinstall the bolts to the correct torque.
Model years: 2000
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Hoses, lines/piping, and fittings (service brakes)
Vehicle description: transit buses. The rear brake release time can exceed the requirements of FMVSS no. 121.
Remedy: Dealers will increase the rear brake delivery lines and the rear brake signal line.
Model years: 1998
Other New Flyer models
- Xcelsior4 complaints
- D40LF2 complaints
- XD602 complaints
- C40FLR1 complaints
- D60LFR1 complaints
- GE40LF1 complaints
- XT401 complaints
- C30LF0 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.