RoadVitals

2005 New Flyer D40I

Recalls, owner-reported complaints, investigations and safety data

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
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Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
5
Latest Sep 20, 2013
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
2
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
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Overview

Our database contains no NHTSA owner-reported complaints for the 2005 New Flyer D40I. 5 safety recalls have been issued covering this model year; 2 NHTSA investigations name it; and 2 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Safety recalls

5 campaigns cover this model year

View all 5

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
13V485000

ELECTRICAL SYSTEM

Sep 20, 2013
57 units potentially affected
The defect: 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.
The risk: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
The 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.
New Flyer Industries Ltd.Manufacturer number R13-021View on NHTSA.gov
09V367000

INTERIOR LIGHTING

Sep 24, 2009
1,412 units potentially affected
The defect: 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.
The risk: A SHORT COULD OCCUR, POSSIBLY CAUSING SMOKE AND FIRE.
The 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 INDUSTRIES LTDView on NHTSA.gov
06V212000

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

Jun 14, 2006
798 units potentially affected
The defect: 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.
The 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.
The 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.
NEW FLYER INDUSTRIES LTDView on NHTSA.gov

Safety investigations

NHTSA inquiries naming this vehicle. An investigation is not a finding of a defect.

EA09010ClosedEngineering Analysis

Air Brake System

Opened Jun 18, 2009
Closed Nov 19, 2010

INVESTIGATION HAS NOT IDENTIFIED A DEFECT.THERE HAVE BEEN NO REPORTED COMPLAINTS RELATING TO THIS ISSUE SINCE 2006. SEE CLOSING REPORT FOR FURTHER DETAILS.

SERVICE BRAKES, AIR
PE09012ClosedPreliminary Evaluation

AIR BRAKE SYSTEM

Opened Feb 27, 2009
Closed Jun 18, 2009

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 BRAKES, AIR:CONTROLS

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

No owner complaints recorded for this model year

Either none have been filed with NHTSA, or this vehicle is too new for reports to have accumulated.

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

PMB049

EQUIPMENT

This Parts Manual Bulletin provides new part number information for the moveable arm kit for the Kongsberg brake and accelerator assembly on specifically equipped vehicles.

SMB178

EQUIPMENT; EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

This 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.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

New Flyer D40I by model year
YearComplaintsRecallsInvestigationsIssue Index
2006020—
2005Viewing052—
2004040—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.