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2004 New Flyer D40LF
The 2004 New Flyer D40LF appears in 9 NHTSA recall campaigns (interior lighting, electrical system and equipment adaptive/mobility) and in 0 consumer complaints filed with the agency.
No consumer complaints for this model year are in the NHTSA file.
Complaints are consumer reports and have not been verified by NHTSA. Recall text is the manufacturer's Part 573 report as filed with NHTSA. Complaint file through 15 May 2019; recall file through 29 Sep 2026.
Recalls by model year:
Recall campaigns
Defect, as filed: 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.
Consequence: A short could occur, possibly causing smoke and fire.
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.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: 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.
Consequence: Due to the very high internal temperatures created at the bearing during shaft seizure, the belt dust may ignite, resulting in an engine compartment fire.
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 duty, narrower belt will shred rather than continue to run over the stationary pulley. The recall began on november 17, 2008. Owners may contact new flyer at 1-204-934-4803.
Filed by NEW FLYER INDUSTRIES LTD (manufacturer campaign R08-016).
Defect, as filed: 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.
Consequence: Separation of the ramp from the vehicle could result in injury to passengers on the ramp.
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.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: 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.
Consequence: Failure of the valve would disable the rear axle service brake circuit and result in extended stopping distances which could result in a crash.
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 204-934-4803.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: 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.
Consequence: In the event of a turbocharger failure there is a possibility of an exhaust or engine compartment fire.
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.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: 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.
Consequence: Leaks caused due to damaged o-rings could cause hydraulic fluid to be sprayed onto hot surfaces and ignite.
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.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: On certain transit buses custom built for southeastern pennsylvania transit authority and equipped with man axles, the center-link assemblies were incorrectly tightened.
Consequence: Improper securing of the center-link rod ends could cause the assembly to come apart, resulting in loss of vehicle steering control, increasing the risk of a crash.
Remedy: Southeastern pennsylvania transit authority was notified of this recall on june 28, 2005. Vehicles will have the subject components replaced.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: 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.
Consequence: Bracket failure could result in a crash without prior warning.
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.
Filed by NEW FLYER INDUSTRIES LTD.
Defect, as filed: On certain transit buses equipped with webasto heaters, the burner tubes are made of material that does not meet specifications and could fail prematurely.
Consequence: Should the burner tube fail, the coolant heater could overheat, possibly resulting in a fire.
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.
Filed by NEW FLYER INDUSTRIES LTD.
Each entry links to the NHTSA record. NHTSA states that safety recall repairs are free of charge at an authorised dealer; check a specific vehicle by VIN at nhtsa.gov/recalls.
Complaints by component
No consumer complaints for this model year are in the NHTSA file.
Investigations
No NHTSA Office of Defects Investigation action in the current file names this model year.
Other New Flyer D40LF model years
| Model year | Recalls | Complaints | Units in campaigns |
|---|---|---|---|
| 1992 NHTSA | 1 | 0 | 48 |
| 1993 NHTSA | 1 | 0 | 469 |
| 1994 | 4 | 0 | 2,630 |
| 1995 | 4 | 0 | 2,630 |
| 1996 | 4 | 0 | 2,402 |
| 1997 | 7 | 0 | 3,965 |
| 1998 | 9 | 1 | 9,644 |
| 1999 | 7 | 0 | 8,137 |
| 2000 | 7 | 0 | 8,116 |
| 2001 | 5 | 1 | 5,167 |
| 2002 | 5 | 0 | 3,998 |
| 2003 | 5 | 0 | 3,236 |
| 2004 | 9 | 0 | 4,298 |
| 2005 | 8 | 0 | 7,196 |
| 2006 | 8 | 0 | 11,229 |
| 2007 | 8 | 0 | 10,389 |
| 2008 | 7 | 0 | 7,414 |
| 2009 | 2 | 0 | 3,893 |
| 2010 NHTSA | 1 | 0 | 4,848 |
Model years with a single campaign and fewer than 25 complaints have no page here; the NHTSA link opens the agency's record for that year.
All New Flyer D40LF model years · New Flyer: 52 model lines
Questions and answers
How many recalls does the 2004 New Flyer D40LF have?
9 NHTSA recall campaigns name this model year; the most recent, 09V367000, was reported to NHTSA on 24 Sep 2009 and concerns interior lighting. Across all model years the New Flyer D40LF line has 41 campaigns.
Is there an open NHTSA investigation into the 2004 New Flyer D40LF?
No NHTSA investigation in the current file names this model year.
What component do owners of the 2004 New Flyer D40LF complain about most?
No complaints for this model year are in the NHTSA file.
How do I get a recall repaired?
NHTSA states that safety recall repairs are performed free of charge by the manufacturer's authorised dealers. Each campaign's remedy text above is the manufacturer's statement as filed with NHTSA. Check your VIN at nhtsa.gov/recalls to see whether a specific vehicle has an unrepaired recall.
Where does this data come from?
NHTSA's Office of Defects Investigation recall, complaint and investigation flat files, public domain, downloaded 29 Sep 2026. Complaint counts are unique complaint numbers per make, model and model year; component figures count each component a complaint names. The NHTSA record linked from each campaign is authoritative.
Provenance
Source: National Highway Traffic Safety Administration, Office of Defects Investigation flat files (recalls, complaints, investigations), public domain, files dated 29 Sep 2026 (recalls) and 15 May 2019 (complaints). Complaints since 1 Jan 1995. Counts are unique complaint numbers per make, model and model year; per-1,000 rates divide a component's mentions by all mentions for the same group. Errors in processing are corrected at the next daily build; see corrections and the methodology.