New Flyer D40LFR recalls by model year

Reported: 2008-11-07 (November 7, 2008) · Model years: 2005

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.

Reported: 2007-03-13 (March 13, 2007) · Model years: 2006

ON CERTAIN TRANSIT BUSES EQUIPPED WITH GRAHAM WHITE AIR DRYERS, THE AIR DRYER TIMER MODULES MAY ALLOW SUFFICIENT QUANTITIES OF MOISTURE TO ENTER AND AFFECT THE OPERATION OF THE VEHICLE AIR BRAKE SYSTEM.

Consequence: FAILURE OF THE AIR BRAKE SYSTEM DUE TO MOISTURE COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE AIR DRYER TIMER MODULE ON THE AFFECTED VEHICLES. THE RECALL BEGAN ON MARCH 22, 2007. OWNERS MAY CONTACT NEW FLYER AT 204-934-4874.

Reported: 2008-01-09 (January 9, 2008) · Model years: 2006, 2007

CERTAIN BUSES HAVE STAINLESS STEEL HYDRAULIC LINES WITH 90º FLANGE FITTINGS WHICH ARE SUBJECT TO FAILURE DUE TO ERRORS IN BOTH THE DESIGN AND MANUFACTURE OF THESE LINES.

Consequence: FAILURE OF THESE LINES, LOCATED IN THE ENGINE COMPARTMENT, COULD RESULT IN A VEHICLE FIRE.

Remedy: NEW FLYER WILL REMOVE THESE LINES AND REPLACE THEM WITH A PREVIOUSLY PROVEN DESIGN OF FLEXIBLE LINES. THE RECALL BEGAN ON JANUARY 15, 2008. OWNERS MAY CONTACT NEW FLYER AT 1-204-982-8400.

Reported: 2009-09-24 (September 24, 2009) · Model years: 2006, 2007

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.

Reported: 2017-03-01 (March 1, 2017) · Model years: 2006, 2007

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.

Reported: 2010-03-09 (March 9, 2010) · Model years: 2007, 2008, 2009

NEW FLYER IS RECALLING CERTAIN MODEL YEAR 2004-2009 TRANSIT BUSES. THESE MODELS HAVE AN INSPECTION PANEL LOCATED ABOVE THE DRIVE SHAFT IN THE PASSENGER COMPARTMENT FLOORING FOR EASY INSPECTION AND REMOVAL OF THE DRIVE SHAFT. THIS PANEL MAY NOT BE OF SUFFICIENT STRENGTH TO PREVENT FOREIGN MATTER FROM ENTERING THE PASSENGER COMPARTMENT IN THE EVENT OF A DRIVE SHAFT FAILURE.

Consequence: FAILURE OF THE DRIVE SHAFT ACCESS PANEL TO MAINTAIN PASSENGER COMPARTMENT INTEGRITY COULD RESULT IN INJURY OR DEATH.

Remedy: DEALERS WILL INCORPORATE AN ENERGY ABSORBING HONEYCOMB MATERIAL TO THE UNDERSIDE OF THE ACCESS PANEL. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MARCH 10, 2010. OWNERS MAY CONTACT NEW FLYER AT 204-934-4874.

Reported: 2011-04-14 (April 14, 2011) · Model years: 2007, 2008, 2009, 2010

NEW FLYER IS RECALLING CERTAIN MODEL YEAR 2007-2011 LOW FLOOR TRANSIT BUSES PRODUCED FROM MAY 24, 2007, THROUGH MARCH 1, 2011 AND EQUIPPED WITH TEETER LEVER ASSEMBLIES. THERE IS INSUFFICIENT ENGAGEMENT BETWEEN THE TEETER LEVER BASE AND THE CAM PLATE.

Consequence: FAILURE OF THE TEETER LEVER ASSEMBLY WILL CAUSE THE REAR SIDE EXIT DOOR TO OPERATE IMPROPERLY. A PASSENGER LEANING ON OR FORCED AGAINST THE DOOR COULD FALL THROUGH THE DOOR AND SUSTAIN INJURIES.

Remedy: NEW FLYER IS WORKING WITH THE MANUFACTURER OF THE TEETER LEVER ASSEMBLIES, VAPOR BUS, TO REPAIR THE AFFECTED BUSES FREE OF CHARGE. PLEASE SEE VAPOR BUS DEFECT REPORT 11E-010. THE SAFETY RECALL BEGAN ON APRIL 29, 2011. OWNERS MAY CONTACT VAPOR BUS AT 1-847-777-6450 OR NEW FLYER CUSTOMER SERVICES AT 1-204-934-4874.

Reported: 2012-12-17 (December 17, 2012) · Model years: 2007, 2008, 2009

New Flyer is recalling certain model year 2004-2011 transit buses, models: C35LF, C40LFR, D35LFR, D40LF, D40LFR, D60LF, D60LFA, D60LFR, DE35LFA, DE40LF, DE40LFA, DE40LFR, DE60LF, DE60LFA, DE60LFR, and XDE40. The drive shaft access panel may have insufficient strength or be not properly secured to the floor. If the drive shaft fails, debris from the driveshaft failure may enter the passenger compartment through the panel.

Consequence: If debris resulting from drive shaft failure enters the passenger compartment, it may result in injury to the bus occupants.

Remedy: New Flyer notification to owners on 01/03/2013. Dealers will install a steel plate under the access panel on affected buses, free of charge. Owners may contact New Flyer at 1-204-224-6706 for more information.

Reported: 2010-07-05 (July 5, 2010) · Model years: 2008

NEW FLYER IS RECALLING CERTAIN MODEL YEAR 2008 D40LFR AND MODEL YEAR 2009 DE60LFR HEAVY DUTY LOW FLOOR TRANSIT BUSES EQUIPPED WITH TRW IGEN3 INTERMEDIATE STEERING COLUMNS. THE WELD AROUND THE IGEN3 STEERING SHAFT TUBE THAT SECURES THE SPLINE TUBE TO THE INTERMEDIATE TUBE MAY BE MIS-LOCATED.

Consequence: MIS-LOCATED WELDS MAY RESULT IN TORSIONAL AND AXIAL STRENGTH FALLING BELOW ACCEPTABLE LEVELS. THIS CONDITION COULD RESULT IN SEPARATION OF THE STEERING COLUMN, LOSS OF STEERING CONTROL AND A VEHICLE CRASH WITHOUT WARNING.

Remedy: THE SAFETY RECALL BEGAN ON AUGUST 2, 2010. TRW IS HANDLING THE REMEDY FOR THIS CAMPAIGN PLEASE SEE TRW'S DEFECT REPORT 10E-026. THE CORRECTIVE ACTION INVOLVES INSPECTION AND REPLACEMENT OF THE STEERING COLUMNS IF FOUND TO BE DEFECTIVE. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. OWNERS MAY CONTACT TRW AT 765-429-1768 OR NEW FLYER CUSTOMER SERVICE AT 204-934-4876.

Reported: 2011-08-22 (August 22, 2011) · Model years: 2010

NEW FLYER IS RECALLING CERTAIN MODEL YEAR 2010 HEAVY DUTY TRANSIT BUSES, MODELS D35LFR, D40LFR, D60LFR, DE40LFR, DE60LFR, XD35, XDE35, AND XDE40, MANUFACTURED FROM SEPTEMBER 30, 2010, THROUGH JUNE 3, 2011, EQUIPPED WITH A CUMMINS ISB, ISL, ISC, or ISX DIESEL ENGINE. THE V-BAND CLAMP ASSEMBLY, PART NUMBERS Q187684, Q187685, AND Q187686, USED TO CONNECT THE INLET AND OUTLET CONE SECTIONS TO THE DIESEL OXIDATION CATALYST (DOC)/DIESEL PARTICULATE FILTER (DPF) INCLUDE A T-BOLT WHICH CAN FRACTURE AND FAIL WHEN SUBJECTED TO STRESS OR LOAD. A FRACTURE OR FAILURE OF THE T-BOLT MAY CAUSE THE CLAMP TO LOOSEN AND THE INLET OR OUTLET SECTIONS ATTACHED TO THE DOC/DPF HOUSING TO DISCONNECT.

Consequence: IF THE INLET OR OUTLET SECTIONS DISCONNECT, HOT EXHAUST GASES CAN VENT PRIOR TO EXITING THE TAILPIPE, CREATING THE RISK OF COMBUSTION AND A FIRE. IF BOTH CLAMPS FAIL, THERE IS A RISK IN SOME APPLICATIONS THAT THE DOC/DPF HOUSING MAY DETACH COMPLETELY, CREATING A ROAD HAZARD.

Remedy: NEW FLYER IS WORKING WITH CUMMINS TO IDENTIFY AND NOTIFY OWNERS OF THE RECALL CAMPAIGN. REPAIRS WILL BE PERFORMED BY AUTHORIZED CUMMINS DEALERS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON SEPTEMBER 1, 2011. OWNERS MAY CONTACT CUMMINS AT 1-812-377-5000 OR NEW FLYER CUSTOMER SERVICES AT 1-204-934-4876.

Reported: 2012-10-25 (October 25, 2012) · Model years: 2011, 2012

New Flyer is recalling certain model year 2010-2012 transit buses, models C40LF, C40LFR, D35LFR, D40LFR, D60LFR, XD35, XD40, XDE35, XDE40, and XN40. Air pressure may leak from the parking brake chambers causing the parking brakes to drag while the vehicle is driven.

Consequence: If the brakes drag, they may overheat, possibly resulting in a fire.

Remedy: New Flyer will notify the owners and the affected brake chambers will be replaced, free of charge. The recall began on November 13, 2012. Owners may contact New Flyer at 1-204-224-6706 for more information.

Reported: 2016-01-26 (January 26, 2016) · Model years: 2011

New Flyer Industries, Ltd. (New Flyer) is recalling certain model year 2015 New Flyer MD30, 2012 C35LFR, 2010-2011 D35LFR, NABI 35LFW, 2011 D40LFR, 2010-2012 D60LFR and NABI 31LFW, 2010 C40LF, DE35LF, D40LF, DE40LFA, DE60LFA, GE35LFR and GE40LF, 2009 DE60LF and GE40LFR, 2010-2013 C40LFR, DE60LFR, NABI 416 and NABI 60BRT, 2010-2015 XD35, XDE40, NABI 40LFW and 42BRT, 2011-2015 XD40 and XN40, 2013-2015 XD60, XDE60 and XN35, 2010-2014 XDE35, 2013 XE40, 2012-2015 XN60, equipped with certain Recaro Ergo-M Commercial Bus Driver Seats. The affected seats have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.

Consequence: If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash, increasing their risk of injury.

Remedy: New Flyer will notify owners instructing them to inspect their seats for missing welds. Recaro will supply replacement anchorage brackets and cover the labor to replace them if any welds are missing, free of charge. The recall began on February 4, 2016. Owners may contact New Flyer customer service at 1-204-224-6706, or Recaro customer service at 1-800-873-2276. New Flyer's number for this recall is R16-001.