2012 New Flyer XN40: complaints, problems and recalls

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: 2013-05-28 (May 28, 2013)

New Flyer Industries is recalling certain model year 2012 XD35 and XD40, model year 2013 XD60, XDE40 and XDE60 and model year 2012-2013 XN40 and XN60 transit buses. In the affected buses, the push-to-start button switch may have a weak return spring, allowing the engine to start unexpectedly.

Consequence: If the engine starts without warning, there is an increased risk for injury to persons working on or near the engine.

Remedy: New Flyer will notify owners, and dealers will inspect and replace the switches free of charge. The recall began June 19, 2013. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's recall number is R13-014.

Reported: 2013-09-20 (September 20, 2013)

New Flyer Industries is recalling certain model year 2012 XN40 transit buses manufactured October 30, 2012, through November 27, 2012, and equipped with certain Sportworks Northwest Apex 3 bicycle racks. In the affected racks, cracks may develop where the latch tube is welded to the pivot tabs connected to the frame. Over time, the cracks may lead to separation of the latch tube and latch handle.

Consequence: If the latch handle and tube fall from the rack it would create a potential road hazard for other vehicles, increasing the risk of a crash.

Remedy: New Flyer will notify owners and Sportworks Northwest will replace the frames under warranty, free of charge. The recall began on October 30, 2013. Owners may contact New Flyer at 1-800-665-2637 or Sportworks at 1-888-861-0555 ext. 2. New Flyer's campaign number is R13-022.

Reported: 2014-03-04 (March 4, 2014)

New Flyer Industries Canada ULC (New Flyer) is recalling certain model year 2009 C35LF and L40LFR, model year 2009-2012 C35LFR, model year 2008-2013 C40LF and C40LFR, model year 2013 XN35, model year 2011-2013 XN40 and model year 2012-2013 XN60 transit buses equipped with certain Cummins Westport Model ISL G engines. In the affected vehicles, condensation in the intake manifold may freeze during cold weather conditions and interfere with the proper operation of the intake manifold pressure sensor.

Consequence: The improper operation of the sensor could induce elevated exhaust temperatures or flames from the exhaust pipe, increasing the risk of a vehicle fire or burn injury to a person near the exhaust pipe.

Remedy: New Flyer will notify owners, and authorized Cummins Inc. and Cummins Wesport Inc. facilities will upload a new ECM calibration, free of charge. The recall began on March 21, 2014. Customers may contact New Flyer at 1-204-934-4876 or Cummins Inc. at 1-800-343-7357. New Flyer's number associated with this recall is R14-006.

Reported: 2015-05-18 (May 18, 2015)

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2009-2012 C35LFR, 2008-2013 C40LF, 2008-2013 C40LFR, 2009 L40LFR, 2009 C35LF, 2013-2014 XN35, 2011-2014 XN40, and 2012-2014 XN60 buses, equipped with certain Cummins Westport ISL G engines. Excessive engine crankcase pressures may cause the 90-degree elbow of the vent tube assembly to detach from the crankcase ventilation breather, possibly allowing engine oil to come into contact with hot surfaces.

Consequence: If the engine oil comes into contact with hot surfaces, it can increase the risk of a vehicle fire.

Remedy: Cummins will notify owners on behalf of New Flyer, and Cummins service centers will administer the repairs which include securing the ends of the 90-degree elbow and reprogramming the electronic control module (ECM) with software that can adjust the engine output under misfire conditions to limit crankcase pressures. These repairs will be performed free of charge. The recall began on June 25, 2015. Owners may contact New Flyer customer service at (204) 224-6706. New Flyer's number for this recall is R15-007.

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.