New Flyer D40LF 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 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.

Risk

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.

Recall number 16V038000 · Recall details

What is wrong

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.

Risk

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.

Recall number 12V591000 · Recall details

What is wrong

New flyer is recalling certain model year 2005-2010 heavy duty transit buses. The three retaining bolts for the output flange on the ise propulsion system are subject to fatigue failure. Failure of the three bolts retaining the output flange to the combination gear box on the ise propulsion system could result in a separation of a portion of the driveshaft, with the output flange attached, from the vehicle.

Risk

Separation of the driveshaft and output flange from the vehicle creates the potential for bodily injury of bystanders and/or property damage.

Remedy

Dealers will inspect the drive line components and replace the output flange bolts free of charge. The safety recall began on august 18, 2011. Owners may contact new flyer at 1‑204‑934‑4876.

Recall number 11V407000 · 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 2008-2009 heavy duty transit buses. The radius rod bracket which attaches the front axle radius rods to the vehicle frame may be missing two of the four required welds.

Risk

Failure of a radius rod bracket assembly may result in restricted steering capability increasing the risk of vehicle crash, injury or death.

Remedy

Dealers will inspect for radius rod brackets and will be replaced with certified product free of charge. The safety recall began on december 13, 2010. Owners may contact new flyer at 1‑204‑934‑4876.

Recall number 10V605000 · Recall details

What is wrong

New flyer is recalling certain model year 2008 c40lfr, d40lf and de60lf heavy duty transit buses, as well as model year 2009 de60lfa heavy duty transit buses. The passenger assist grab strap handles have experienced multiple failures in the field.

Risk

Failure of a passenger assist grab strap handle could result in a passenger falling and being injured.

Remedy

Dealers will replace the existing passenger assist grab strap handles with an improved product free of charge. The safety recall is expected to begin during august 2010. Owners may contact new flyer at 1‑204‑934‑4876.

Recall number 10V343000 · Recall details

What is wrong

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.

Risk

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.

Recall number 10V089000 · 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 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.

Risk

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.

Recall number 08V586000 · 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

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.

Risk

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.

Recall number 07V103000 · 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 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 manufactured with detroit diesel series 50 engines, the electronic control module (ECM) will need to be reprogrammed to activate the exhaust temperature sensor.

Risk

In the event of a turbocharger failure there is a possibility of an exhaust or engine compartment fire.

Remedy

New flyer is working with detroit diesel to reprogram the engines. Owners may contact detroit diesel at 1‑313‑592‑5791 or new flyer at 204‑934‑4876.

Recall number 05V421000 · 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 detroit diesel series 40 engines, the turbocharger can fail allowing lubricating oil to spill onto the engine.

Risk

This can result in a fire in the engine compartment.

Remedy

Dealers will inspect and replace the turbocharger to prevent the possibility of an engine compartment fire. Detroit diesel is conducting the owner notification and remedy for this campaign. Owners may contact detroit diesel at 313‑592‑3708 or new flyer at 1‑204‑982‑8400.

Recall number 05V320000 · Recall details

What is wrong

On certain transit buses custom built for southeastern pennsylvania transit authority and equipped with man axles, the center-link assemblies were incorrectly tightened.

Risk

Improper securing of the center-link rod ends could cause the assembly to come apart, resulting in loss of vehicle steering control, increasing the risk of a crash.

Remedy

Southeastern pennsylvania transit authority was notified of this recall on june 28, 2005. Vehicles will have the subject components replaced.

Recall number 05V298000 · 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 transit buses equipped with a voith transmission, the cooler line can rub on the auxiliary heater exhaust.

Risk

This could cause a transmission fluid leak. If the fluid leaks onto the hot exhaust system it could result in a vehicle fire.

Remedy

Dealers will modify the transmission cooler hose assembly and add a fitting to promote additional clearance. Owner notification began during february 2004. Owners should contact new flyer at 1‑204‑982‑8400.

Recall number 04V076000 · 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: transit buses. Five (5) front radius rods installed in these buses have failed.

Risk

A failure of a front radius rod could cause a shift in the front axle, possibly resulting in a loss of vehicle control.

Remedy

Dealers will replace the radius rod. Owner notification began march 1, 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 01V074000 · Recall details

What is wrong

Vehicle description: transit buses. The front axle's spring tower bolts may not have been adequately tightened.

Risk

Incorrect bolt torque could lead to a shorter bolt fatigue life and eventual bolt failure.

Remedy

Dealers will reinstall the bolts to the correct torque.

Recall number 00V276000 · 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 equipped with an auxiliary diesel powered heater (proheat bravo model 80). An improperly assembled fuel regulator can allow an excess amount of fuel into the combustion chamber.

Risk

This leakage can lead to a potential for flames to escape from the heater exhaust.

Remedy

Teleflex canada, the manufacturer of the heater, will inspect and, if necessary, replace all defective regulators.

Recall number 98V141000 · Recall details

What is wrong

Vehicle description: transit buses. A tether strap on the driver's seat was omitted. This does not comply with the strength requirements of fmvss no. 207, seating systems."

Risk

The driver seat may not adequately restrain the driver in the event of a vehicle crash.

Remedy

The owner will be provided with parts, instructions and repair assistance as required. The owner will install the missing tether straps.

Recall number 98V138000 · Recall details

What is wrong

The brake release timing does not meet the requirements of fmvss no. 121, "air brake systems."

Risk

Consequence of non-compliance: premature brake wear could cause increased stopping distances increasing the risk of a vehicle accident.

Remedy

Owners will be provided with parts, instructions and assistance in restoring the brake timing to fmvss 121 requirements.

Recall number 95V239001 · Recall details

What is wrong

Vehicle description: transit buses owned by the new york port authority. The left front suspension radius rod bolts did not provide sufficient clamping of the radius rod pin causing the pin to rotate in its mounting blocks leading to bolt failure.

Risk

If both bolts failed, the axle would detach from the vehicle increasing the risk of loss of vehicle control.

Remedy

All buses have been corrected. No further remedy is planned.

Recall number 97V132000 · 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

What is wrong

Vehicle description: buses equipped with isringhausen seats in the driver position. Two welds located on the back rest adjustment side of the seat frame did not meet the manufacturer's specifications.

Risk

If these welds were not to specification, back rest loads could cause the welds to fail. The back rest would disengage from the seat frame allowing loss of support to the driver's torso and possibly causing loss of control of the vehicle.

Remedy

Isringhausen is conducting the owner notification and remedy campaign for this recall. Dealers will inspect these seats and replace the seat frame assembly.

Recall number 96V178009 · Recall details

What is wrong

The brake release timing does not meet the requirements of fmvss no. 121, "air brake systems."

Risk

Consequence of non-compliance: premature brake wear could cause increased stopping distances increasing the risk of a vehicle accident.

Remedy

Owners will be provided with parts, instructions and assistance in restoring the brake timing to fmvss 121 requirements.

Recall number 95V239000 · Recall details