2005 New Flyer D40LF
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › New Flyer › D40LF › 2005
These records cover every 2005 New Flyer D40LF. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
8 recalls name the 2005 New Flyer D40LF. Newest first.
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…
Risk and remedy
Risk
Failure of the front axle beam can cause a loss of vehicle control, increasing the risk of a crash.
Remedy
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.
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.
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…
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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
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.
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.
Risk and remedy
Risk
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.
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.
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.
Risk and remedy
Risk
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.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Air Brake System
Investigation has not identified a defect.there have been no reported complaints relating to this issue since 2006. See closing report for further details.
- Air brake system
Odi IS closing this preliminary evaluation and opening an engineering analysis (ea09-010) to further identify and evaluate the vehicle environment and brake system factors that may be causing or contributing to extended stopping distance performance in certain vehicles.
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.
- 10144750This Service Manual Bulletin Provides Updated Preventive Maintenace Interval for the Crankcase Breather Tube Element on Buses Equipped with a Cummins Diesel ISL 07 or ISL 09 Engine.
- 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.
- 10042651New flyer: information concerning the relocation of the leveling valves in the rear. No model years listed.
- 10031204New flyer: install alternator support bracket. Models include 40FT, 60FT, dsl, and elec low floor. No model years listed.
Every New Flyer D40LF model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.