2004 New Flyer D40I
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › New Flyer › D40I › 2004
These records cover every 2004 New Flyer D40I. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
4 recalls name the 2004 New Flyer D40I. Newest first.
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…
Risk and remedy
Risk
Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
Remedy
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.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10128680This Service Manual Bulletin provides new OEM (Kongsberg) PM inspection requirements and new installation procedure for the adjustable floor pedal moveable arm on specifically equipped vehicles.
- 10128679This Parts Manual Bulletin provides new part number information for the moveable arm kit for the Kongsberg brake and accelerator assembly on specifically equipped vehicles.
Every New Flyer D40I model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.