2004 New Flyer D40LF recalls
9 NHTSA recall campaigns naming the 2004 New Flyer D40LF. Last verified Jul 30, 2026. Recalls may apply only to certain VIN ranges — always confirm with a VIN check.
Units are totals reported across campaigns mentioning this model — NHTSA does not always break unit counts down by model.
Affected components
Nearby model years
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Campaigns
- Sep 24, 2009Fire risk2002 New Flyer C30LF, 2002–2007 New Flyer C35LF, 2004–2006 New Flyer C40LF and 13 other models — 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.
09V367000 · 1K units · NEW FLYER INDUSTRIES LTD
- Nov 7, 2008Fire risk2004–2007 New Flyer D40LF, 2005 New Flyer D40LFR, 2007–2008 New Flyer D60LFR — 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 CONTINUES TO PASS OVER THE PULLEY CREATING HIGH QUANTITIES OF BELT DUST.
08V586000 · 1K units · NEW FLYER INDUSTRIES LTD
- Feb 7, 2006Crash risk2004–2005 New Flyer C30LF, 2004–2005 New Flyer C35LF, 2004–2005 New Flyer C40LF and 6 other models — 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.
06V034000 · 682 units · NEW FLYER INDUSTRIES LTD
- Jan 18, 2006Crash risk2004–2005 New Flyer C40LF, 2004–2005 New Flyer D40I, 2004–2005 New Flyer D40LF and 2 other models — Service Brakes, Air
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.
06V015000 · 103 units · NEW FLYER INDUSTRIES LTD
- Sep 22, 2005Fire risk2003–2004 New Flyer D40LF — 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.
05V421000 · 11 units · NEW FLYER INDUSTRIES LTD
- Aug 25, 2005Safety2004–2005 New Flyer C30LF, 2004–2005 New Flyer C40LF, 2004–2005 New Flyer D30LF and 4 other models — 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.
05V370000 · 665 units · NEW FLYER INDUSTRIES LTD
- Jun 27, 2005Crash risk2004 New Flyer D40LF — Steering
ON CERTAIN TRANSIT BUSES CUSTOM BUILT FOR SOUTHEASTERN PENNSYLVANIA TRANSIT AUTHORITY AND EQUIPPED WITH MAN AXLES, THE CENTER-LINK ASSEMBLIES WERE INCORRECTLY TIGHTENED.
05V298000 · 218 units · NEW FLYER INDUSTRIES LTD
- Mar 25, 2005Crash risk2004–2005 New Flyer C35LF, 2004–2005 New Flyer C40LF, 2004–2005 New Flyer D30LF and 4 other models — 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.
05V116000 · 178 units · NEW FLYER INDUSTRIES LTD
- Mar 16, 2005Fire risk2004 New Flyer D35LF, 2003–2004 New Flyer D40LF — 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.
05V100000 · 28 units · NEW FLYER INDUSTRIES LTD