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2005 New Flyer D40I recalls

Source: NHTSA data as of September 22, 2026. Last refreshed Sep 23, 2026, 2:43 AM UTC.

5 recalls found in NHTSA data as of September 22, 2026

For the 2005 New Flyer D40I. These apply to the model and year, not to one particular vehicle: check your VIN to see whether yours is included and whether it has been repaired.

Has your New Flyer been repaired?

Recalls here come from NHTSA’s records for the model and year. Not every vehicle of a model is included in every recall, and this site can’t see whether a repair has been done. Only a VIN lookup can tell you that.

NHTSA’s VIN search doesn’t show recalls that were already repaired, recalls more than 15 years old, or some small manufacturers’ recalls. A New Flyer dealer can also check your VIN. Recall repairs are free.

2005 New Flyer D40I recalls, newest first

September 20, 2013NHTSA 13V48500057 vehicles potentially affected

Electrical system

Summary
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.
Consequence
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.

This recall on nhtsa.gov

September 24, 2009NHTSA 09V3670001,412 vehicles potentially affected

Interior lighting

Summary
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.

This recall on nhtsa.gov

June 14, 2006NHTSA 06V212000798 vehicles potentially affected

Engine and engine cooling › Engine › Diesel

Summary
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
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.

This recall on nhtsa.gov

January 18, 2006NHTSA 06V015000103 vehicles potentially affected

Service brakes, air › Supply › Check valve

Summary
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.

This recall on nhtsa.gov

August 25, 2005NHTSA 05V370000665 vehicles potentially affected

Engine and engine cooling › Cooling system › Fan

Summary
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.

This recall on nhtsa.gov

Owner complaints

No owner complaints about the 2005 New Flyer D40I were found in NHTSA’s complaint data.

Other New Flyer D40I years

Other 2005 New Flyer models

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All of 2005’s most recalled vehicles

Questions

Does the 2005 New Flyer D40I have any recalls?
5 recalls found in NHTSA data as of September 22, 2026, covering: electrical system, interior lighting, engine and engine cooling, service brakes, air. Recalls apply to the model and year; whether a particular vehicle is included, and whether it has been repaired, depends on its VIN.
How do I check if my 2005 New Flyer D40I recall has been fixed?
Enter your 17-character VIN at nhtsa.gov/recalls, or ask a New Flyer dealer. Recall repairs are free. NHTSA's VIN search doesn't list recalls that were already repaired.
How many complaints have owners filed about the 2005 New Flyer D40I?
0 complaints filed with NHTSA. Complaints are unverified reports from the public that NHTSA uses to decide what to investigate.