How many recalls does the 2004 New Flyer D40LF have?

NHTSA lists 9 recall campaigns for the 2004 New Flyer D40LF as of October 16, 2026. Each includes the defect description, safety consequence, and the remedy New Flyer will perform. New recalls can be issued at any time; this page is refreshed from NHTSA daily.

How do I tell if my 2004 New Flyer D40LF is affected by a recall?

Enter your 17-character VIN — stamped at the base of the windshield on the driver side and on the door jamb sticker — at nhtsa.gov/recalls. NHTSA's VIN lookup shows whether your specific vehicle has an unrepaired recall; the list on this page covers every campaign for the 2004 New Flyer D40LF.

Are recall repairs on a 2004 New Flyer D40LF free?

Usually. Federal law requires New Flyer to remedy recalls on the 2004 D40LF free of charge at an authorized New Flyer dealer, regardless of how many owners the vehicle has had or how many miles are on the odometer — unless it was first sold more than 15 years before the recall was issued (5 years for tires).

Does a recall on the 2004 New Flyer D40LF affect resale value?

An open recall can reduce resale value; a recall that has been repaired (documented in the vehicle history report) generally does not. Before you buy or sell a used 2004 New Flyer D40LF, check the VIN at nhtsa.gov/recalls to confirm every recall has been remedied.

How many owner complaints are on file for the 2004 New Flyer D40LF?

No owner complaints have been filed with NHTSA on the 2004 New Flyer D40LF.

NHTSA vehicle safety data

2004 New Flyer D40LF Recalls, Ratings & Complaints

The 2004 New Flyer D40LF has 9 NHTSA recall campaigns and 0 owner complaints on file as of October 16, 2026. Recall repairs are usually free at an authorized New Flyer dealer.

NHTSA recall and complaint data for the 2004 New Flyer D40LF. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

INTERIOR LIGHTING

NHTSA #09V367000

Reported September 24, 2009 · NEW FLYER INDUSTRIES LTD

Potentially affected: 1,412 vehicles

Defect description

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.

Safety consequence

A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.

Manufacturer 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.

Notes

OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

ELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATOR

NHTSA #08V586000

Reported November 7, 2008 · NEW FLYER INDUSTRIES LTD

Potentially affected: 1,001 vehicles

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

NEW FLYER RECALL NO. R08-016.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

EQUIPMENT ADAPTIVE/MOBILITY

NHTSA #06V034000

Reported February 7, 2006 · NEW FLYER INDUSTRIES LTD

Potentially affected: 682 vehicles

Defect description

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.

Safety consequence

SEPARATION OF THE RAMP FROM THE VEHICLE COULD RESULT IN INJURY TO PASSENGERS ON THE RAMP.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

SERVICE BRAKES, AIR:SUPPLY:CHECK VALVE

NHTSA #06V015000

Reported January 18, 2006 · NEW FLYER INDUSTRIES LTD

Potentially affected: 103 vehicles

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

NHTSA #05V421000

Reported September 22, 2005 · NEW FLYER INDUSTRIES LTD

Potentially affected: 11 vehicles

Defect description

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.

Safety consequence

IN THE EVENT OF A TURBOCHARGER FAILURE THERE IS A POSSIBILITY OF AN EXHAUST OR ENGINE COMPARTMENT FIRE.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

ENGINE AND ENGINE COOLING:COOLING SYSTEM:FAN

NHTSA #05V370000

Reported August 25, 2005 · NEW FLYER INDUSTRIES LTD

Potentially affected: 665 vehicles

Defect description

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.

Safety consequence

LEAKS CAUSED DUE TO DAMAGED O-RINGS COULD CAUSE HYDRAULIC FLUID TO BE SPRAYED ONTO HOT SURFACES AND IGNITE.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

STEERING:LINKAGES

NHTSA #05V298000

Reported June 27, 2005 · NEW FLYER INDUSTRIES LTD

Potentially affected: 218 vehicles

Defect description

ON CERTAIN TRANSIT BUSES CUSTOM BUILT FOR SOUTHEASTERN PENNSYLVANIA TRANSIT AUTHORITY AND EQUIPPED WITH MAN AXLES, THE CENTER-LINK ASSEMBLIES WERE INCORRECTLY TIGHTENED.

Safety 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.

Manufacturer remedy

SOUTHEASTERN PENNSYLVANIA TRANSIT AUTHORITY WAS NOTIFIED OF THIS RECALL ON JUNE 28, 2005. VEHICLES WILL HAVE THE SUBJECT COMPONENTS REPLACED.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

STEERING:LINKAGES:TIE ROD ASSEMBLY

NHTSA #05V116000

Reported March 25, 2005 · NEW FLYER INDUSTRIES LTD

Potentially affected: 178 vehicles

Defect description

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.

Safety consequence

BRACKET FAILURE COULD RESULT IN A CRASH WITHOUT PRIOR WARNING.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

ENGINE AND ENGINE COOLING

NHTSA #05V100000

Reported March 16, 2005 · NEW FLYER INDUSTRIES LTD

Potentially affected: 28 vehicles

Defect description

ON CERTAIN TRANSIT BUSES EQUIPPED WITH WEBASTO HEATERS, THE BURNER TUBES ARE MADE OF MATERIAL THAT DOES NOT MEET SPECIFICATIONS AND COULD FAIL PREMATURELY.

Safety consequence

SHOULD THE BURNER TUBE FAIL, THE COOLANT HEATER COULD OVERHEAT, POSSIBLY RESULTING IN A FIRE.

Manufacturer 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.

Notes

CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

Other New Flyer D40LF model years

Check your 2004 New Flyer D40LF VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your New Flyer D40LF at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

Check a New Flyer VIN