New Flyer D35LF recalls

What is wrong

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.

Risk

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.

Recall number 17V130000 · Recall details

What is wrong

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.

Risk

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.

Recall number 11V237000 · Recall details

What is wrong

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.

Risk

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.

Recall number 09V367000 · Recall details

What is wrong

New flyer is recalling 319 my 2008 c40lf, c40lfr, d35lf, d40lf, d41lf, d61lfr, de41lf, de61lf, e40lfr, ge40lfr, and de41lfr transit buses equipped with parker hannifin (vansco) control modules. A certain batch of the programmable logic control modules may have a manufacturing defect. This defect could produce erratic behavior of certain input/output signals to and from the affected module. This erratic behavior could potentially impact certain functions such as the headlights, brake lights, throttle control, and control of the articulated joint.

Risk

Failure of the module to properly control the vehicle sub-systems could result in vehicle crash, injury or death.

Remedy

The affected modules will be replaced free of charge. The recall began on july 14, 2008. Owners may contact new flyer at 1‑204‑982‑8400.

Recall number 08V296000 · Recall details

What is wrong

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.

Risk

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.

Recall number 08V010000 · Recall details

What is wrong

Certain transit buses fail to comply with the requirements of federal motor vehicle safety standard no. 108, "lamps reflective devices, and associated equipment." the flashing deceleration lamps were an optional item for some of these buses.

Risk

The standard requires that the deceleration lamp is a solid light rather than a flashing light.

Remedy

Dealers will rewire the electrical system to remove the flashing function or install a new programmable logic controller (plc) which will make the lamps burn steady free of charge. The recall began on march 5, 2007. Owners may contact new flyer at 204‑934‑4874.

Recall number 07V068000 · Recall details

What is wrong

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.

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.

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.

Recall number 06V212000 · Recall details

What is wrong

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.

Risk

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.

Recall number 06V034000 · Recall details

What is wrong

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.

Risk

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.

Recall number 05V370000 · Recall details

What is wrong

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.

Risk

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.

Recall number 05V116000 · Recall details

What is wrong

On certain transit buses equipped with webasto heaters, the burner tubes are made of material that does not meet specifications and could fail prematurely.

Risk

Should the burner tube fail, the coolant heater could overheat, possibly resulting in a fire.

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.

Recall number 05V100000 · Recall details

What is wrong

On certain low floor buses, the power steering hose was incorrectly installed.

Risk

The hose can leak, creating the risk of an engine fire.

Remedy

Dealers will replace the hose. Owner notification began july 1, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact new flyer at 1‑204‑228‑8984.

Recall number 02V112000 · Recall details

What is wrong

On certain buses equipped with electronic throttle control/accelerator pedals supplied by williams controls industries, the weld attaching the clevis to the plate has insufficient penetration and could allow the clevis to separate from the plate.

Risk

If the clevis separated from the plate while the vehicle was in use, the vehicle would return to idle, increasing the risk of a crash.

Remedy

Williams controls is handling the replacement of this pedal. Owners who do not receive the free remedy within a reasonable time should contact williams control at 1‑503‑684‑8600 or new flyer at 204‑982‑8181.

Recall number 02V004008 · Recall details

What is wrong

On certain low floor transit buses equipped with adhesively bonded aluminum bus door panels, due to an imperfect bonding of the door panel skin to the panel frame, environmental moisture may infiltrate regions of imperfect bonding and cause separation of the frame and door panel.

Risk

Under these conditions, if the panel is separating or has separated, a passenger could fall from the bus onto the roadway, possibly resulting in personal injury or death.

Remedy

Vapor will notify customers to have their buses inspected and will install mechanical fasteners to attach the skins to the frame elements free of charge. Owner notification began december 10, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact vapor corporation at 847‑967‑8300 or new flyer at 1‑204‑224‑1251.

Recall number 02V059001 · Recall details

What is wrong

Vehicle description: transit buses. The clamp nuts for the center link tie rods may have been inadequately tightened.

Risk

Inadequately tightened clamp nuts could lead to the tie rods separating from the center link possibly resulting in a vehicle crash.

Remedy

New flyer will will inspect the tie rod end clamp lock nuts to ensure that the nuts are properly tightened. Any damaged tie rods will be replaced. Owner notification began september 17, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact new flyer at 1‑204‑982‑8181.

Recall number 01V265000 · Recall details

What is wrong

Vehicle description: transit buses. There could be a casting defect in the left side spring tower. The spring towers support the vehicle structure, and failure of a tower could cause a sudden shift in the front axle.

Risk

This condition could lead to loss of control of the vehicle.

Remedy

Dealers will replace the spring tower. Owner notification is expected to begin during may 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact new flyer at 1‑204‑982‑8181.

Recall number 01V160000 · Recall details

What is wrong

Vehicle description: transit buses equipped with vanner 60 series battery equalizers. The equalizer could fail to operate properly and cause malfunction of the battery charging system.

Risk

Without fusing, the equalizer may melt, burn, or smoke, possibly resulting in a fire or a smoke filled bus, thus necessitating a passenger evacuation of the bus. The failure mode can cause operator distraction, and/or possible personal injury.

Remedy

Dealers will inspect the buses for certain equalizers by the date code. The affected equalizers will be replaced by vanner. New flyer is conducting the owner notification for this campaign. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact vanner at 1‑800‑227‑6937 or new flyer at 1‑204‑982‑8413.

Recall number 01V033006 · Recall details

What is wrong

Vehicle description: certain transit buses equipped with ABS fail to comply with the requirements of fmvss no. 121, "air brake systems." the rear brake release time can exceed the requirements.

Risk

A slow brake release can cause premature brake wear, increasing the risk of a crash.

Remedy

The repair will involve installing a quick release valve or increasing the size of the rear brake control line.

Recall number 00V275000 · Recall details

What is wrong

Vehicle description: transit buses. The rear brake release time can exceed the requirements of fmvss no. 121.

Risk

A slow brake release can cause premature brake wear which if left unchecked could lead to brake failure and vehicle crash.

Remedy

Dealers will increase the rear brake delivery lines and the rear brake signal line.

Recall number 99V077000 · Recall details

What is wrong

Vehicle description: transit buses. The daytime running lamp (drl) module can over-heat and shut down after as little as 45 minutes of high beam use. This will cause total headlamp failure of both high and low beam.

Risk

If the drl module over-heats and the headlamps go out, there is a significant risk of a vehicle crash.

Remedy

Owners will be provided with detailed repair instructions and new drl modules.

Recall number 97V103000 · Recall details