New Flyer D40LF Recalls & Complaints by Model Year
NHTSA lists 41 safety recalls and 2 owner complaints across 19 model years of the New Flyer D40LF (1992–2010). The most-complained-about year is 1998.
Pick your New Flyer D40LF model year
| Model year | Recalls | Complaints |
|---|---|---|
| 2010 New Flyer D40LF | 1 | 0 |
| 2009 New Flyer D40LF | 2 | 0 |
| 2008 New Flyer D40LF | 7 | 0 |
| 2007 New Flyer D40LF | 8 | 0 |
| 2006 New Flyer D40LF | 8 | 0 |
| 2005 New Flyer D40LF | 8 | 0 |
| 2004 New Flyer D40LF | 9 | 0 |
| 2003 New Flyer D40LF | 5 | 0 |
| 2002 New Flyer D40LF | 5 | 0 |
| 2001 New Flyer D40LF | 5 | 1 |
| 2000 New Flyer D40LF | 7 | 0 |
| 1999 New Flyer D40LF | 7 | 0 |
| 1998 New Flyer D40LF | 9 | 1 |
| 1997 New Flyer D40LF | 7 | 0 |
| 1996 New Flyer D40LF | 4 | 0 |
| 1995 New Flyer D40LF | 4 | 0 |
| 1994 New Flyer D40LF | 4 | 0 |
| 1993 New Flyer D40LF | 1 | 0 |
| 1992 New Flyer D40LF | 1 | 0 |
What New Flyer D40LF owners complain about
Across all model years, owners have filed 2 complaints with NHTSA. The 1998 model year has the most, with 1.
All New Flyer D40LF recalls (41)
Every NHTSA safety campaign that lists a New Flyer D40LF, 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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Structure
New Flyer is recalling certain model year 2004-2011 transit buses, models: C35LF, C40LFR, D35LFR, D40LF, D40LFR, D60LF, D60LFA, D60LFR, DE35LFA, DE40LF, DE40LFA, DE40LFR, DE60LF, DE60LFA, DE60LFR, and XDE40. The drive shaft access panel may have insufficient strength or be not properly secured to the floor. If the drive shaft fails,…
Remedy: New Flyer notification to owners on 01/03/2013. Dealers will install a steel plate under the access panel on affected buses, free of charge. Owners may contact New Flyer at 1-204-224-6706 for more information.
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Driveshaft (power train)
New flyer is recalling certain model year 2005-2010 heavy duty transit buses. The three retaining bolts for the output flange on the ise propulsion system are subject to fatigue failure. Failure of the three bolts retaining the output flange to the combination gear box on the ise propulsion system could result in a separation of a…
Remedy: Dealers will inspect the drive line components and replace the output flange bolts free of charge. The safety recall began on august 18, 2011. Owners may contact new flyer at 1-204-934-4876.
Model years: 2007
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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.…
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Axle assembly (power train)
New flyer is recalling certain model year 2008-2009 heavy duty transit buses. The radius rod bracket which attaches the front axle radius rods to the vehicle frame may be missing two of the four required welds.
Remedy: Dealers will inspect for radius rod brackets and will be replaced with certified product free of charge. The safety recall began on december 13, 2010. Owners may contact new flyer at 1-204-934-4876.
Model years: 2008
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Equipment
New flyer is recalling certain model year 2008 c40lfr, d40lf and de60lf heavy duty transit buses, as well as model year 2009 de60lfa heavy duty transit buses. The passenger assist grab strap handles have experienced multiple failures in the field.
Remedy: Dealers will replace the existing passenger assist grab strap handles with an improved product free of charge. The safety recall is expected to begin during august 2010. Owners may contact new flyer at 1-204-934-4876.
Model years: 2008
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Driveshaft (power train)
New flyer is recalling certain model year 2004-2009 transit buses. These models have an inspection panel located above the drive shaft in the passenger compartment flooring for easy inspection and removal of the drive shaft. This panel may not be of sufficient strength to prevent foreign matter from entering the passenger compartment in…
Remedy: Dealers will incorporate an energy absorbing honeycomb material to the underside of the access panel. This service will be performed free of charge. The safety recall began on march 10, 2010. Owners may contact new…
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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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Alternator/generator/regulator (electrical system)
New flyer is recalling 1,001 my 2004-2007 d40lf, my 2005 d40lfr, and my 2007-2008 d60lfr transit buses equipped with ce niehoff c701a or c703a alternators. Failure of the forward alternator bearing may result in a drop and seizure of the rotating alternator shaft and pulley. Once the pulley is stationary, the alternator drive belt…
Remedy: To increase the potential longevity of the alternator bearings, dealers will incorporate a lower tension belt tensioner and a narrower belt. To prevent thermal ignition in the event of a bearing failure, a lighter…
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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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Engine (engine and engine cooling)
Certain buses have stainless steel hydraulic lines with 90º flange fittings which are subject to failure due to errors in both the design and manufacture of these lines.
Remedy: New flyer will remove these lines and replace them with a previously proven design of flexible lines. The recall began on january 15, 2008. Owners may contact new flyer at 1-204-982-8400.
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Service brakes, air: control unit/module
On certain transit buses equipped with graham white air dryers, the air dryer timer modules may allow sufficient quantities of moisture to enter and affect the operation of the vehicle air brake system.
Remedy: Dealers will replace the air dryer timer module on the affected vehicles. The recall began on march 22, 2007. Owners may contact new flyer at 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: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
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Diesel (engine and engine cooling)
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.
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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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Exhaust system (engine and engine cooling)
On certain transit buses manufactured with detroit diesel series 50 engines, the electronic control module (ECM) will need to be reprogrammed to activate the exhaust temperature sensor.
Remedy: New flyer is working with detroit diesel to reprogram the engines. Owners may contact detroit diesel at 1-313-592-5791 or new flyer at 204-934-4876.
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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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Turbo/supercharger (engine and engine cooling)
On certain transit buses equipped with detroit diesel series 40 engines, the turbocharger can fail allowing lubricating oil to spill onto the engine.
Remedy: Dealers will inspect and replace the turbocharger to prevent the possibility of an engine compartment fire. Detroit diesel is conducting the owner notification and remedy for this campaign. Owners may contact detroit…
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Linkages (steering)
On certain transit buses custom built for southeastern pennsylvania transit authority and equipped with man axles, the center-link assemblies were incorrectly tightened.
Remedy: Southeastern pennsylvania transit authority was notified of this recall on june 28, 2005. Vehicles will have the subject components replaced.
Model years: 2004
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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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Engine and engine cooling
On certain transit buses equipped with webasto heaters, the burner tubes are made of material that does not meet specifications and could fail prematurely.
Remedy: Dealers will replace the suspected defective parts free of charge. The recall began on march 15, 2005. Owners may contact new flyer at customer services at 204-934-4874.
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Cooling unit and lines (power train)
On certain transit buses equipped with a voith transmission, the cooler line can rub on the auxiliary heater exhaust.
Remedy: Dealers will modify the transmission cooler hose assembly and add a fitting to promote additional clearance. Owner notification began during february 2004. Owners should contact new flyer at 1-204-982-8400.
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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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Suspension
Vehicle description: transit buses. Five (5) front radius rods installed in these buses have failed.
Remedy: Dealers will replace the radius rod. Owner notification began march 1, 2001. 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…
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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
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Seats
Vehicle description: transit buses. A tether strap on the driver's seat was omitted. This does not comply with the strength requirements of FMVSS no. 207, seating systems."
Remedy: The owner will be provided with parts, instructions and repair assistance as required. The owner will install the missing tether straps.
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Defroster/defogger/hvac system (visibility)
Vehicle description: transit buses equipped with an auxiliary diesel powered heater (proheat bravo model 80). An improperly assembled fuel regulator can allow an excess amount of fuel into the combustion chamber.
Remedy: Teleflex canada, the manufacturer of the heater, will inspect and, if necessary, replace all defective regulators.
Model years: 1997
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Service brakes, air
The brake release timing does not meet the requirements of FMVSS no. 121, "air brake systems."
Remedy: Owners will be provided with parts, instructions and assistance in restoring the brake timing to FMVSS 121 requirements.
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Suspension: front
Vehicle description: transit buses owned by the new york port authority. The left front suspension radius rod bolts did not provide sufficient clamping of the radius rod pin causing the pin to rotate in its mounting blocks leading to bolt failure.
Remedy: All buses have been corrected. No further remedy is planned.
Model years: 1992
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Headlights (exterior lighting)
Vehicle description: transit buses. The daytime running lamp (drl) module can over-heat and shut down after as little as 45 minutes of high beam use. This will cause total headlamp failure of both high and low beam.
Remedy: Owners will be provided with detailed repair instructions and new drl modules.
Model years: 1997
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Seats
Vehicle description: buses equipped with isringhausen seats in the driver position. Two welds located on the back rest adjustment side of the seat frame did not meet the manufacturer's specifications.
Remedy: Isringhausen is conducting the owner notification and remedy campaign for this recall. Dealers will inspect these seats and replace the seat frame assembly.
Model years: 1996
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Service brakes, air
The brake release timing does not meet the requirements of FMVSS no. 121, "air brake systems."
Remedy: Owners will be provided with parts, instructions and assistance in restoring the brake timing to FMVSS 121 requirements.
Other New Flyer models
- Xcelsior4 complaints
- XD602 complaints
- C40FLR1 complaints
- C40LF1 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.