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New Flyer D40I Recalls & Complaints by Model Year

NHTSA lists 5 safety recalls and 0 owner complaints across 3 model years of the New Flyer D40I (2004–2006).

5
safety recalls, all years
0
owner complaints, all years
2005
year with most recalls

Pick your New Flyer D40I model year

Model yearRecallsComplaints
2006 New Flyer D40I20
2005 New Flyer D40I50
2004 New Flyer D40I40

All New Flyer D40I recalls (5)

Every NHTSA safety campaign that lists a New Flyer D40I, most recent first, with the model years each one covers.

  1. Electrical system

    NHTSA 13V485000 Reported 57 vehicles potentially affected New Flyer Industries Ltd.

    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…

    Remedy: New 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…

    Model years: 2004, 2005, 2006

  2. Interior lighting

    NHTSA 09V367000 Reported 1,412 vehicles potentially affected NEW FLYER INDUSTRIES LTD

    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.

    Model years: 2004, 2005, 2006

  3. Diesel (engine and engine cooling)

    NHTSA 06V212000 Reported 798 vehicles potentially affected NEW FLYER INDUSTRIES LTD

    On certain transit buses built with cummins isl and isc diesel engines equipped with the cm850 fuel system, the engine high pressure fuel lines, from the engine high pressure pump to the engine fuel rail, are prone to failure.

    Remedy: Cummins will install a fuel line bracket to reduce fuel line stress. A new fuel line will be installed when adding the bracket. Customers may contact cummins at 1-800-diesels or new flyer at 204-934-4876.

    Model years: 2005

  4. Check valve (service brakes)

    NHTSA 06V015000 Reported 103 vehicles potentially affected NEW FLYER INDUSTRIES LTD

    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…

    Model years: 2004, 2005

  5. Fan (engine and engine cooling)

    NHTSA 05V370000 Reported 665 vehicles potentially affected NEW FLYER INDUSTRIES LTD

    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.

    Model years: 2004, 2005

Other New Flyer models

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.