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2004 New Flyer D40LF recalls

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

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

For the 2004 New Flyer D40LF. 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.

2004 New Flyer D40LF recalls, newest first

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

November 7, 2008NHTSA 08V5860001,001 vehicles potentially affected

Electrical system › Alternator/generator/regulator

Summary
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.

This recall on nhtsa.gov

February 7, 2006NHTSA 06V034000682 vehicles potentially affected

Equipment adaptive/mobility

Summary
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.

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

September 22, 2005NHTSA 05V42100011 vehicles potentially affected

Engine and engine cooling › Exhaust system

Summary
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.

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

June 27, 2005NHTSA 05V298000218 vehicles potentially affected

Steering › Linkages

Summary
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.

This recall on nhtsa.gov

March 25, 2005NHTSA 05V116000178 vehicles potentially affected

Steering › Linkages › Tie rod assembly

Summary
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.

This recall on nhtsa.gov

March 16, 2005NHTSA 05V10000028 vehicles potentially affected

Engine and engine cooling

Summary
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.

This recall on nhtsa.gov

Owner complaints

No owner complaints about the 2004 New Flyer D40LF were found in NHTSA’s complaint data.

Other New Flyer D40LF years

Other 2004 New Flyer models

Most recalled 2004 vehicles

  1. 2004 Honda Accord (22 recalls)
  2. 2004 Ford E-250 (18 recalls)
  3. 2004 Blue Bird Vision (17 recalls)
  4. 2004 Ford F-150 (16 recalls)
  5. 2004 Chevrolet Silverado (15 recalls)
All of 2004’s most recalled vehicles

Questions

Does the 2004 New Flyer D40LF have any recalls?
9 recalls found in NHTSA data as of September 22, 2026, covering: interior lighting, electrical system, equipment adaptive/mobility, service brakes, air, engine and engine cooling, steering. 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 2004 New Flyer D40LF 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 2004 New Flyer D40LF?
0 complaints filed with NHTSA. Complaints are unverified reports from the public that NHTSA uses to decide what to investigate.