VehicleVerdict

2004 New Flyer C40lf problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 0 complaints on file for the 2004 New Flyer C40lf — too few to judge reliability from owner reports alone — but 6 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

0

NHTSA complaints

6

Recalls

0

Investigations

0

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other C40lf years?

C40lf NHTSA complaints by model year, 2004 highlighted1 complaint1996: 0 complaints1997: 1 complaints1998: 0 complaints1999: 0 complaints2000: 0 complaints2001: 0 complaints2002: 0 complaints2003: 0 complaints2004: 0 complaints2005: 0 complaints2006: 0 complaints2007: 0 complaints2008: 0 complaints2009: 0 complaints2010: 0 complaints2011: 0 complaints2012: 0 complaints2013: 0 complaints
C40lf NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all C40lf years to avoid →

Does the 2004 New Flyer C40lf have recalls?

6 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

09V367000LightingSeptember 24, 2009 · 1,412 units

Defect

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.

Consequence

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.

07V068000LightingFebruary 23, 2007 · 1,707 units

Defect

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.

Consequence

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.

06V034000OtherFebruary 7, 2006 · 682 units

Defect

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.

Consequence

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.

06V015000BrakesJanuary 18, 2006 · 103 units

Defect

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.

Consequence

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.

05V370000EngineAugust 25, 2005 · 665 units

Defect

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.

Consequence

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.

05V116000SteeringMarch 25, 2005 · 178 units

Defect

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.

Consequence

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.

2004 New Flyer C40lf — common questions

Is the 2004 New Flyer C40lf reliable?

The record is thin — 0 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 6 recalls should be verified as completed.

Does the 2004 New Flyer C40lf have recalls?

Yes — NHTSA lists 6 recall campaigns affecting the 2004 New Flyer C40lf. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.