2012 New Flyer XDE40: complaints, problems and recalls

Reported: 2012-01-04 (January 4, 2012)

NEW FLYER IS RECALLING CERTAIN MODEL YEARS 2009-2012 XDE40, MODEL YEARS 2010-2011 MODELS XD35 AND XDE35, MODEL YEAR 2010 XD40, AND MODEL YEAR 2011 XN40 TRANSIT BUSES, MANUFACTURED FROM JANUARY 2010, THROUGH DECEMBER 2011, AND EQUIPPED WITH A PARKER-HANNIFIN (VANSCO) INSTRUMENT PANEL. THE PROGRAMMING OF THE INSTRUMENT PANEL IS SUCH THAT IF MULTIPLE ERROR MESSAGES ARE RECEIVED BY THE INSTRUMENT PANEL FROM THE VEHICLE POWERTRAIN, THE “CHECK ENGINE” AND/OR “STOP ENGINE” INDICATOR LAMPS ON THE DASH MAY NOT ILLUMINATE AND THE ENGINE MAY ENTER A SAFETY OR SHUTDOWN MODE OF OPERATION.

Consequence: ENGINE SHUTDOWN WOULD RESULT IN LOSS OF VEHICLE PROPULSION OR VEHICLE STALL, EITHER OF WHICH INCREASES THE RISK OF A CRASH.

Remedy: NEW FLYER WILL REPROGRAM THE INSTRUMENT PANEL FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 9, 2012. NEW FLYER WILL UPLOAD A CORRECTED SOFTWARE VERSION FREE OF CHARGE. OWNERS MAY CONTACT NEW FLYER AT 1-204-934-4876.

Reported: 2012-03-26 (March 26, 2012)

NEW FLYER IS RECALLING CERTAIN MODEL YEAR 2011 XDE35 AND MODEL YEAR 2010-2012 XDE40 HEAVY DUTY TRANSIT BUSES. OVER TIME PARTICULATE DEBRIS CAN ACCUMULATE IN THE LITHIUM-ION ENERGY STORAGE SYSTEM (ESS), AND IN CONJUNCTION WITH MOISTURE, CAN BREACH THE ELECTRICAL ISOLATION OF THE HIGH VOLTAGE BATTERY PACK. A CONDUCTIVE PATH CAN BE CREATED IF THE ELECTRICAL ISOLATION IS BREACHED AT BOTH ENDS OF THE BATTERY.

Consequence: IF THIS CONDITION OCCURS, UNINTENTIONAL DISCHARGE OF THE BATTERY’S STORED ENERGY CAN RESULT, INCREASING THE RISK OF A FIRE.

Remedy: NEW FLYER WILL NOTIFY OWNERS, AND DEALERS WILL INSTALL AN ELECTRICAL CONTACTOR AND MODIFY THE LI-ION ESS, FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 5, 2012. OWNERS MAY CONTACT NEW FLYER AT 1-204-224-6706.

Reported: 2012-10-25 (October 25, 2012)

New Flyer is recalling certain model year 2010-2012 transit buses, models C40LF, C40LFR, D35LFR, D40LFR, D60LFR, XD35, XD40, XDE35, XDE40, and XN40. Air pressure may leak from the parking brake chambers causing the parking brakes to drag while the vehicle is driven.

Consequence: If the brakes drag, they may overheat, possibly resulting in a fire.

Remedy: New Flyer will notify the owners and the affected brake chambers will be replaced, free of charge. The recall began on November 13, 2012. Owners may contact New Flyer at 1-204-224-6706 for more information.

Reported: 2016-01-26 (January 26, 2016)

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.

Consequence: 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.