2005 New Flyer D40lfr Recalls

Recalls on record Updated July 2026

The 2005 New Flyer D40lfr has 1 NHTSA recall campaign affecting an estimated 1,001 vehicles. Recall repairs are always free at any authorized dealer. Last updated July 5, 2026.

Recall campaigns

ELECTRICAL SYSTEM 08V586000 2008-11-07 1,001 affected
Defect

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…

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…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2005 New Flyer D40lfr as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.