2004 New Flyer D40I Problems: 0 Complaints, 4 Recalls

The worst 2004 New Flyer D40I problems

Ranked by number of owner complaints. Mileage and cost come from what owners wrote.

Tap a problem to see which part fails, at what mileage and in which other years.

Electrical systemReported September 20, 2013 · 57 vehicles affected

What is wrong: 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.
Risk: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
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.

Recall number 13V485000 · Recall details

Interior lightingReported September 24, 2009 · 1,412 vehicles affected

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

Service brakes, air: supply: check valveReported January 18, 2006 · 103 vehicles affected

What is wrong: 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.
Risk: Failure of the valve would disable the rear axle service brake circuit and result in extended stopping distances which could result in a crash.
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.

Recall number 06V015000 · Recall details

Engine and engine cooling: cooling system: fanReported August 25, 2005 · 665 vehicles affected

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

Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.

Is the 2004 New Flyer D40I reliable?

Owners have filed 0 complaints about the 2004 New Flyer D40I.

What is the most common problem with the 2004 New Flyer D40I?

There are not enough complaints to tell.

How many recalls does the 2004 New Flyer D40I have?

4 recalls, covering electrical system, interior lighting and service brakes, air.

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