VehicleVerdict

2003 New Flyer D40lf problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 0 complaints on file for the 2003 New Flyer D40lf — too few to judge reliability from owner reports alone — but 5 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

0

NHTSA complaints

5

Recalls

0

Investigations

0

Crash-involved

0

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2003 compare to other D40lf years?

D40lf NHTSA complaints by model year, 2003 highlighted3 complaints1992: 0 complaints1993: 0 complaints1994: 0 complaints1995: 0 complaints1996: 0 complaints1997: 0 complaints1998: 3 complaints1999: 0 complaints2000: 0 complaints2001: 1 complaints2002: 0 complaints2003: 0 complaints2004: 0 complaints2005: 0 complaints2006: 0 complaints2007: 0 complaints2008: 0 complaints2009: 0 complaints2010: 0 complaints
D40lf NHTSA complaints by model year, 2003 highlighted. Red bars are years to avoid.

See all D40lf years to avoid →

Does the 2003 New Flyer D40lf have recalls?

5 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.

05V421000EngineSeptember 22, 2005 · 11 units

Defect

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.

Consequence

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.

05V100000EngineMarch 16, 2005 · 28 units

Defect

ON CERTAIN TRANSIT BUSES EQUIPPED WITH WEBASTO HEATERS, THE BURNER TUBES ARE MADE OF MATERIAL THAT DOES NOT MEET SPECIFICATIONS AND COULD FAIL PREMATURELY.

Consequence

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.

04V076000TransmissionFebruary 17, 2004 · 78 units

Defect

ON CERTAIN TRANSIT BUSES EQUIPPED WITH A VOITH TRANSMISSION, THE COOLER LINE CAN RUB ON THE AUXILIARY HEATER EXHAUST.

Consequence

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.

2003 New Flyer D40lf — common questions

Is the 2003 New Flyer D40lf reliable?

The record is thin — 0 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 5 recalls should be verified as completed.

Does the 2003 New Flyer D40lf have recalls?

Yes — NHTSA lists 5 recall campaigns affecting the 2003 New Flyer D40lf. 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.