2005 New Flyer D40I problems

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

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

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 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

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

Investigation has not identified a defect.there have been no reported complaints relating to this issue since 2006. See closing report for further details.

EA09010

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.

PE09012