2006 New Flyer D40LF: complaints, problems and recalls

Reported: 2006-06-14 (June 14, 2006)

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.

Reported: 2007-03-13 (March 13, 2007)

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)

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: 2008-11-07 (November 7, 2008)

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: 2009-09-24 (September 24, 2009)

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: 2010-03-09 (March 9, 2010)

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: 2012-12-17 (December 17, 2012)

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: 2017-03-01 (March 1, 2017)

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.