RecallMyCar

2004 New Flyer D40I Recalls, Complaints & Specs

4 safety recalls list the 2004 New Flyer D40I. Check your own VIN below.

4
safety recalls
0
owner complaints to NHTSA

4 safety recalls for the 2004 New Flyer D40I

Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.

  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…

  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.

  3. 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…

  4. 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.

No owner complaints on file

NHTSA has no owner complaints on file for the 2004 New Flyer D40I. For context, the average model year in NHTSA's database has dozens; a zero can mean a reliable vehicle, a rare one, or both.

Compare New Flyer D40I model years

Recall and complaint counts for every New Flyer D40I model year in NHTSA's database.

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

Checking a specific 2004 New Flyer D40I

How do I know if my 2004 New Flyer D40I has an open recall?

Enter your 17-character VIN above. The VIN is on the driver's side dashboard (visible through the windshield), the driver's door jamb sticker, and your registration or insurance card. The check runs against NHTSA's live database and tells you which campaigns list your vehicle. 4 campaigns currently list the 2004 New Flyer D40I; your car may already have been repaired under some of them.

Is the recall repair free?

Yes. Under federal law, manufacturers must fix safety recalls at no charge for vehicles up to 15 years old from the date of sale to the first owner. Contact any authorised New Flyer dealer with your VIN and the NHTSA campaign number (for example 05V370000).

What is the difference between a recall and a complaint?

A recall is a safety campaign filed by the manufacturer or ordered by NHTSA, with a defined defect and remedy. A complaint is a report an owner sent to NHTSA; it is not verified, but patterns of complaints are what trigger NHTSA investigations and, eventually, recalls.

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.