2005 New Flyer D40LF: recalls and complaints

NHTSA lists 8 recall campaigns for the 2005 New Flyer D40LF. The newest campaign is 17V130000. NHTSA received the report on 1 Mar 2017. The NHTSA record gives the component Suspension / Front. NHTSA has no complaint on file for this model year. 2 NHTSA investigations name this model year.

The NHTSA recall file shows no do-not-drive advisory and no park-outside advisory on these campaigns.

This page cannot show if a recall applies to one vehicle. The NHTSA VIN lookup shows the unrepaired recalls of one vehicle.

Remedy of the newest campaign, 17V130000, in the NHTSA record

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 1-204-224-6706. New Flyer's number for this recall is R17-002.

NHTSA VIN lookup

Complaint information entered into NHTSA’s Office of Defects Investigation vehicle owner's complaint database is used with other data sources to identify safety issues that warrant investigation and to determine if a safety-related defect trend exists.
NHTSA publishes these words. Source: NHTSA Datasets and APIs, section Complaints, read on 1 Oct 2026. Complaint file through 29 Mar 2018. Recall file through 29 Sep 2026.

Since the last update

No tracked figure of this page changed in a data update. What the log tracks

All updates to the register

Recall campaigns

8 campaigns, newest first. 7,196 units in total.

17V1300001 Mar 2017Suspension / Front
09V36700024 Sep 2009Interior Lighting
08V5860007 Nov 2008Electrical System / Alternator/Generator/Regulator
06V21200014 Jun 2006Engine and Engine Cooling / Engine / Diesel
06V0340007 Feb 2006Equipment Adaptive/Mobility
06V01500018 Jan 2006Service Brakes, Air / Supply / Check Valve
05V37000025 Aug 2005Engine and Engine Cooling / Cooling System / Fan
05V11600025 Mar 2005Steering / Linkages / Tie Rod Assembly

17V130000Received 1 Mar 2017. 2,357 units.
Suspension / Front
Defect, in the NHTSA record
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 cracks on the upper and/or lower surface, which, over time can cause the axle beam to fail.
Consequence, in the NHTSA record
Failure of the front axle beam can cause a loss of vehicle control, increasing the risk of a crash.
Remedy, in the NHTSA record
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 1-204-224-6706. New Flyer's number for this recall is R17-002.
Report filed by New Flyer Industries Ltd.. Manufacturer campaign number R17-002. Owner notification date in the NHTSA record: 10 Mar 2017.
09V367000Received 24 Sep 2009. 1,412 units.
Interior Lighting
Defect, in the NHTSA record
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, in the NHTSA record
A short could occur, possibly causing smoke and fire.
Remedy, in the NHTSA record
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.
Report filed by NEW FLYER INDUSTRIES LTD. Owner notification date in the NHTSA record: 2 Oct 2009.
08V586000Received 7 Nov 2008. 1,001 units.
Electrical System / Alternator/Generator/Regulator
Defect, in the NHTSA record
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, in the NHTSA record
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, in the NHTSA record
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.
Report filed by NEW FLYER INDUSTRIES LTD. Manufacturer campaign number R08-016. Owner notification date in the NHTSA record: 17 Nov 2008.
06V212000Received 14 Jun 2006. 798 units.
Engine and Engine Cooling / Engine / Diesel
Defect, in the NHTSA record
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.
Consequence, in the NHTSA record
Failure of the line introduces high pressure fuel spray into the engine compartment which can ignite when it comes in contact with a hot surface.
Remedy, in the NHTSA record
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.
Report filed by NEW FLYER INDUSTRIES LTD. Owner notification date in the NHTSA record: 22 Jun 2006.
06V034000Received 7 Feb 2006. 682 units.
Equipment Adaptive/Mobility
Defect, in the NHTSA record
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, in the NHTSA record
Separation of the ramp from the vehicle could result in injury to passengers on the ramp.
Remedy, in the NHTSA record
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.
Report filed by NEW FLYER INDUSTRIES LTD. Owner notification date in the NHTSA record: 15 Feb 2006.
06V015000Received 18 Jan 2006. 103 units.
Service Brakes, Air / Supply / Check Valve
Defect, in the NHTSA record
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, in the NHTSA record
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, in the NHTSA record
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.
Report filed by NEW FLYER INDUSTRIES LTD. Owner notification date in the NHTSA record: 25 Jan 2006.
05V370000Received 25 Aug 2005. 665 units.
Engine and Engine Cooling / Cooling System / Fan
Defect, in the NHTSA record
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, in the NHTSA record
Leaks caused due to damaged o-rings could cause hydraulic fluid to be sprayed onto hot surfaces and ignite.
Remedy, in the NHTSA record
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.
Report filed by NEW FLYER INDUSTRIES LTD. Owner notification date in the NHTSA record: 30 Aug 2005.
05V116000Received 25 Mar 2005. 178 units.
Steering / Linkages / Tie Rod Assembly
Defect, in the NHTSA record
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, in the NHTSA record
Bracket failure could result in a crash without prior warning.
Remedy, in the NHTSA record
Dealers will replace the brackets free of charge. The recall began on april 6, 2005. Owners may contact new flyer at 204-934-4874.
Report filed by NEW FLYER INDUSTRIES LTD. Owner notification date in the NHTSA record: 6 Apr 2005.

The campaign number opens the NHTSA record. Each quotation is the text of the NHTSA recall file.

Recall campaign: One recall in the NHTSA recall file, with one campaign number. A campaign can name many makes, models and model years.

Units: The number of vehicles or products that a recall can include. The manufacturer or the firm reports the number to the agency.

Complaints by component

The NHTSA complaint file has no complaint for this model year.

Investigations

NHTSA investigations that name the 2005 New Flyer D40LF
Number	Type	Subject	Component	Opened	Closed	Campaign
EA09010	Engineering analysis	Air Brake System	Service Brakes, Air	18 Jun 2009	19 Nov 2010
PE09012	Preliminary evaluation	AIR BRAKE SYSTEM	Service Brakes, Air / Controls	27 Feb 2009	18 Jun 2009

Investigation: A study of a possible safety defect by the NHTSA Office of Defects Investigation. An investigation with no closing date in the NHTSA file is open.

Other model years

The number under each year is the number of recall campaigns.

A year without a link has fewer than 2 campaigns and fewer than 25 complaints. It has no page.

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Official channels

NHTSA VIN lookupNHTSA shows the unrepaired recalls of one vehicle from its VIN or its license plate.
NHTSA: report a safety problemThe NHTSA form for a complaint about a vehicle, a tire, a child seat or equipment.
NHTSA page of the 2005 New Flyer D40LFThe recalls, the complaints and the investigations that NHTSA shows for this model year.

Cite this page

Recall Register. 2005 New Flyer D40LF: recalls and complaints. https://recallregister.com/vehicle/new-flyer/d40lf/2005/. Source: NHTSA Office of Defects Investigation, recall, complaint and investigation files. Data through 29 Sep 2026.

Sources

Source: NHTSA Office of Defects Investigation
Licence: US government work, public domain
Recall file through: 29 Sep 2026
Complaint file through: 29 Mar 2018
First complaint in the file: 1 Jan 1995
Manufacturer in the recall file: New Flyer Industries Ltd.

The NHTSA record is the authority. A complaint count is the number of different complaint numbers for the make, the model and the model year. How the register is made. Report an error.

Questions

How many units are in the recall campaigns for the 2005 New Flyer D40LF?: 7,196 units in 8 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the New Flyer D40LF have for all model years?: NHTSA lists 41 recall campaigns for the New Flyer D40LF, model years 1992 to 2010. 8 of them name the 2005 model year.
Is an NHTSA investigation of the 2005 New Flyer D40LF open?: No. Each of the 2 investigations that name this model year has a closing date in the NHTSA file.