In North Carolina, I-40 merges with I-85 between Greensboro and Hillsborough, just west of Durham. In Alamance County, the highway is also known as the Sam Hunt Freeway. Due to a recent rerouting of I-85 around Greensboro, I-40 departs from it eight miles (13 km) east of the original split. However, I-40 will be moved to a new alignment south of Greensboro, which currently carries the new I-85 bypass and will eventually carry Interstate 73 as well. The existing I-40 through Greensboro will become a second I-40 freeway Business Loop once the new alignment is finished by 2007. The concurrency with I-85 will be extended another 12 miles (19 km) on this new alignment.
In violation of Interstate standards, I-40 has one marked and two unmarked at-grade crossings in western North Carolina. About eight miles (13 km) from the Tennessee border in North Carolina, when going westbound, a sign for "Hurricane Road" will appear. Hurricane Road is a local dirt road whose quality is below that of the breakdown lane, and the intersection is controlled by a stop sign. It is a right-in, right-out entrance. A couple other unmarked local roads also directly link onto I-40 in the area, including a private access road for Walters Dam between mile markers 11 and 12 on the westbound side.