New Flyer Xd40 — Lights And Instruments
High risk
Dec 19, 2025
Model years: 2020, 2025
On certain transit buses, a software problem could cause the antilock braking system (ABS) warning light not to turn on if there's a problem with the ABS.
Also affects: New Flyer Xd60, New Flyer Xde40, New Flyer Xe35, New Flyer Xe40, New Flyer Xe60
New Flyer Xd40 — Structure
High risk
Aug 22, 2025
Model years: 2015, 2017, 2019, 2020, 2021, 2024
Certain transit buses may not have enough emergency exits or the exits may be in the wrong location. As a result, the buses don't meet certain requirements of Canadian regulations.
Also affects: New Flyer Xd35, New Flyer Xe40, New Flyer Xe60, New Flyer Xhe40, New Flyer Xhe60
New Flyer Xd40 — Fuel System
High risk
Feb 3, 2025
Model years: 2024
Issue: On certain buses, the remote fuel filter hoses may not have been manufactured properly. As a result, a fuel hose could disconnect and fuel could leak. This could also cause
Also affects: New Flyer Xde60, New Flyer Xd60
New Flyer Xd40 — Powertrain
High risk
Oct 26, 2023
Model years: 2019, 2020, 2021, 2022, 2024
On certain transit buses, the transmission yoke bolt could loosen and cause the driveshaft to separate from the transmission. If this happens, there would be a sudden loss of power
Also affects: New Flyer Xd35
New Flyer Xd40 — Fuel System
High risk
May 18, 2021
Model years: 2017, 2018, 2019, 2020, 2021
Issue: On certain buses, the fuel rail assembly could develop a leak. Note: This recall only affects buses equipped with a Cummins L9 diesel engine. Safety Risk: A fuel leak can cr
Also affects: New Flyer Xde60, New Flyer Xd60, New Flyer Xd35
New Flyer Xd40 — Powertrain
High risk
Mar 8, 2018
Model years: 2017
On certain buses, the sidewalls of the driveshaft's slip yoke were modified and may fracture and fatigue because they are too thin. This could result in failure of the driveshaft,
Also affects: New Flyer Xd60, New Flyer Xde40, New Flyer Xde60, New Flyer Xn40
New Flyer Xd40 — Brakes
High risk
Jan 9, 2018
Model years: 2017
On certain buses, the connections from the front air brake hoses to the ABS modulator valves may not have been tightened to specification during assembly. If the connections were t
Also affects: New Flyer Xd60, New Flyer Xde60
New Flyer Xd40 — Seats And Restraints
High risk
Aug 31, 2017
Model years: 2017
On certain buses, the latching mechanism of the driver's seat belt buckle may prevent the tongue of the seat belt from being inserted into the latch assembly. If the seat belt is u
Also affects: New Flyer Md30, New Flyer Xd60, New Flyer Xde40
New Flyer Xd40 — Structure
High risk
Apr 15, 2016
Model years: 2013, 2014, 2015
On certain buses, the software for the Electric Transit Operator (ETO) control module which controls the rear passenger exit door may contain an error. This could result in a highe
Also affects: New Flyer Xd60, New Flyer Xde60, New Flyer Xn40
New Flyer Xd40 — Seats And Restraints
High risk
Jan 22, 2016
Model years: 2011, 2012, 2013, 2014, 2015
Certain buses equipped with a Recaro ERGO-M driver seats may be missing welds on the seat structure. As a result, the seatbelt anchorage assembly could separate from the seat struc
Also affects: New Flyer D40lf, New Flyer D40lfr, New Flyer D60lfr, New Flyer Xd60, New Flyer Xde40
New Flyer Xd40 — Suspension
High risk
Sep 3, 2015
Model years: 2014
On certain buses, a tie rod end retaining clamp from the center link tube assembly on the front axle may have not have been torqued to specification during front end alignment adju
Also affects: New Flyer Xn40
New Flyer Xd40 — Structure
High risk
May 21, 2015
Model years: 2013, 2014
On certain buses, the software installed that controls the electronic door controller assemblies may be incorrect. The software programming in the controller may misinterpret door
Also affects: New Flyer Xd60, New Flyer Xe40, New Flyer Xn40
New Flyer Xd40 — Brakes
High risk
Sep 4, 2014
Model years: 2013, 2014
On certain vehicles, insufficient clearance through the brake pedal mounting plate can result in improper alignment between the brake pedal assembly and the brake valve actuator. T
Also affects: New Flyer Xd60, New Flyer Xde60, New Flyer Xe40, New Flyer Xn40
New Flyer Xd40 — Powertrain
High risk
Aug 19, 2014
Model years: 2013, 2014
On certain vehicles equipped with Cummins ISB or ISL engines, the fuel filter shell and nut plate could separate, causing a fuel leak and also causing the engine to stall. Stalling
Also affects: New Flyer Md35 Midi
New Flyer Xd40 — Brakes
High risk
Oct 2, 2013
Model years: 2013
On certain buses, air brake circuits at the treadle valve may have been crossed during assembly. In the event of an air leak in the rear air reservoir, this would result in a loss
New Flyer Xd40 — Electrical
High risk
May 24, 2013
Model years: 2012, 2013
On certain buses, the push-button ignition switch could fail to return after being depressed. This would allow the engine to start unexpectedly when the ignition circuit is re-ener
Also affects: New Flyer Xde60
New Flyer Xd40 — Brakes
High risk
Oct 24, 2012
Model years: 2010, 2011, 2012
On certain buses, the brake chambers may develop an air leak, which could cause partial parking brake application. Parking brake drag could result in a fire causing property damage
Also affects: New Flyer D60lfr, New Flyer Xde40, New Flyer Xde60, New Flyer Xn60
New Flyer Xd40 — Engine
High risk
Dec 28, 2011
Model years: 2008, 2010, 2011
On certain buses, the instrument panel may fail to display the "Check Engine" or "Stop Engine" indicator lamps. As a result, the engine may enter de-rate or shutdown mode without g
Also affects: New Flyer Xde40, New Flyer Xn60
New Flyer Xd40 — Engine
High risk
Aug 18, 2011
Model years: 2010
On certain buses equipped with a Cummins engine, the V-band clamps used to connect the inlet and outlet cone sections to the Diesel Oxidation Catalyst (DOC) / Diesel Particulate Fi
Also affects: New Flyer D40lfr, New Flyer D60lfr