Recall 13V485 affects 57 2004-2006 New Flyer D40I transit buses for battery equalizer and converter fire risk. Repair is free at franchised New Flyer dealers.
New Flyer is recalling 57 2004-2006 D40I transit buses because Sure Power battery equalizers and DC-DC converters use an epoxy potting compound that can conduct electricity after heat exposure. Once conductive, the material can melt and burn, increasing fire risk; the New Flyer dealer repair will be free once available.
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What's wrong?
The 2004-2006 New Flyer D40I uses battery equalizers and DC-DC converters as part of the electrical system. These parts manage voltage between battery circuits and bus equipment, so lights, controls, and other electrical loads receive the correct power without overloading one side of the battery system.
In the recalled buses, the Sure Power units contain an epoxy sealing compound, also called potting compound, that surrounds internal electrical parts for insulation. After exposure to heat, that compound can conduct electricity instead of blocking it. That gives current a path through material that is supposed to separate electrical circuits, which can create an electrical fault inside the unit.
There is no warning sign before failure. A driver or maintenance crew should not expect a dashboard message, smell, or change in bus operation before the equalizer or converter fails.
Who's affected?
The included years all point to the same electrical system component.
| 2005 New Flyer D40I | electrical system |
|---|---|
| 2006 New Flyer D40I | electrical system |
| 2004 New Flyer D40I | electrical system |
| Units affected | 57 |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific bus.
What's the safety risk?
Electrically conductive material can melt and burn, increasing the risk of a fire. Keep the bus in service only with caution, and schedule the recall repair with the servicing dealer. If there is heat, smoke, or burning, park safely and call for service. Repair will be free at any franchised New Flyer dealer once available.
What should I do?
- Check your VIN to confirm your 2004-2006 New Flyer D40I is included in this recall.
- Contact a franchised New Flyer dealer to ask about the free equalizer and DC-DC converter replacement.
- Schedule the equalizer and converter replacement that removes the heat-exposed potting compound linked to electrical melting and fire risk.
- Bring the recall notice if New Flyer mailed one. If not, reference recall number 13V485 when you call.
- Call New Flyer at 1-204-982-8400 with questions and ask for recall R13-021.
What happens at the repair
At the dealer, a New Flyer technician replaces the Sure Power battery equalizers and DC-DC converters identified in recall 13V485. These parts contain the epoxy potting compound described in the filing, so the repair removes the affected electrical components instead of asking the owner to monitor them. The dealer repair will be free once available. Parts and labor are covered under the recall.
Timeline
| September 20, 2013 | NHTSA published the recall |
|---|---|
| November 4, 2013 | Owner notification mailed |
Frequently asked questions
What is recall 13V485?
Recall 13V485 covers 57 2004-2006 New Flyer D40I transit buses with Sure Power battery equalizers and DC-DC converters. Heat exposure can make the epoxy potting compound conduct electricity, which can lead to melting, burning, and fire risk.
What should I do if my 2004-2006 New Flyer D40I is on this recall?
Check your VIN to confirm your specific bus is included in recall 13V485. If it is, contact a franchised New Flyer dealer or New Flyer at 1-204-982-8400 and reference recall R13-021. Dealers replace the equalizers and converters for free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and New Flyer's remedy states that dealers replace the affected equalizers and converters free of charge.
What is the safety risk?
The safety risk is fire. The affected potting compound can become electrically conductive after heat exposure. Once conductive, the material can melt and burn, increasing the risk of a fire in the electrical system.
What if I bought this New Flyer D40I used?
The free repair still applies. Recall coverage follows the VIN, not the first owner. Check your VIN to confirm whether your specific D40I is included, then contact a franchised New Flyer dealer or New Flyer with recall number 13V485.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/13V485000 |
|---|---|
| New Flyer customer service | 1-204-982-8400 |
| NHTSA recall # | 13V485 |
| NHTSA recall # (full) | 13V485000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Recall Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Defect / Noncompliance Notice (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on June 2, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →