2004 New Flyer D40LF Recalls, Complaints & Specs
9 safety recalls list the 2004 New Flyer D40LF. Check your own VIN below.
9 safety recalls for the 2004 New Flyer D40LF
Most recent first. Recall repairs are free at any authorised dealer. Click a recall for the full defect, consequence and remedy text.
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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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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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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.
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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.
No owner complaints on file
NHTSA has no owner complaints on file for the 2004 New Flyer D40LF. 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 D40LF model years
Recall and complaint counts for every New Flyer D40LF model year in NHTSA's database.
| Model year | Recalls | Complaints |
|---|---|---|
| 1992 New Flyer D40LF | 1 | 0 |
| 1993 New Flyer D40LF | 1 | 0 |
| 1994 New Flyer D40LF | 4 | 0 |
| 1995 New Flyer D40LF | 4 | 0 |
| 1996 New Flyer D40LF | 4 | 0 |
| 1997 New Flyer D40LF | 7 | 0 |
| 1998 New Flyer D40LF | 9 | 1 |
| 1999 New Flyer D40LF | 7 | 0 |
| 2000 New Flyer D40LF | 7 | 0 |
| 2001 New Flyer D40LF | 5 | 1 |
| 2002 New Flyer D40LF | 5 | 0 |
| 2003 New Flyer D40LF | 5 | 0 |
| 2004 New Flyer D40LF | 9 | 0 |
| 2005 New Flyer D40LF | 8 | 0 |
| 2006 New Flyer D40LF | 8 | 0 |
| 2007 New Flyer D40LF | 8 | 0 |
| 2008 New Flyer D40LF | 7 | 0 |
| 2009 New Flyer D40LF | 2 | 0 |
| 2010 New Flyer D40LF | 1 | 0 |
Checking a specific 2004 New Flyer D40LF
How do I know if my 2004 New Flyer D40LF 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. 9 campaigns currently list the 2004 New Flyer D40LF; 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 05V100000).
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
- 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.