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2005 New Flyer D40LF recalls

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

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

For the 2005 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.

2005 New Flyer D40LF recalls, newest first

March 1, 2017NHTSA 17V1300002,357 vehicles potentially affected

Suspension › Front

Summary
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
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.

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

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

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

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

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

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

Owner complaints

No owner complaints about the 2005 New Flyer D40LF were found in NHTSA’s complaint data.

Other New Flyer D40LF years

Other 2005 New Flyer models

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All of 2005’s most recalled vehicles

Questions

Does the 2005 New Flyer D40LF have any recalls?
8 recalls found in NHTSA data as of September 22, 2026, covering: suspension, interior lighting, electrical system, engine and engine cooling, equipment adaptive/mobility, 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 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 2005 New Flyer D40LF?
0 complaints filed with NHTSA. Complaints are unverified reports from the public that NHTSA uses to decide what to investigate.