2004–2006 New Flyer D40I Recall: Specific potting compound used in the subject products for insulation was…
NHTSA campaign 13V485000 · Electrical System · filed Sep 20, 2013 · verified Jul 30, 2026
The defect
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 found to be capable of conducting electricity after being exposed to heat.
The risk
Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
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 →The fix — what to do
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 R13-021.
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.
Affected vehicles
Related recalls
More New Flyer D40I recalls
- 2002 New Flyer C30LF and 15 other models — Interior Lighting
- 2003–2005 New Flyer D30LF and 5 other models — ON CERTAIN TRANSIT BUSES BUILT WITH CUMMINS ISL AND ISC…
- 2004–2005 New Flyer C40LF and 4 other models — ON CERTAIN TRANSIT BUSES EQUIPPED WITH RELAY VALVES BUILT…
- 2004–2005 New Flyer C30LF and 6 other models — ON CERTAIN TRANSIT BUSES, HYDRAULIC FLUID CAN LEAK AT THE…
Other campaigns involving New Flyer vehicles
Source: NHTSA recall database, campaign 13V485000 (manufacturer number R13-021). Data last verified Jul 30, 2026.