New Flyer XE40 recalls by model year

Reported: 2014-09-04 (September 4, 2014) · Model years: 2013

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 XD35, XDE35, XE40, and 2013-2014 XD40, XD60, XDE40, XDE60, XN35, XN40, and XN60 transit buses. During installation, the Brake Pedal Mounting Plate may have been clamped between the Brake Pedal Assembly and the Brake Valve Actuator (BVA) resulting in a misalignment and binding of the internal piston in the BVA.

Consequence: The binding of the piston may result in increased resistance while applying the brakes and the potential for brake drag once the brake pedal is released. These conditions increase the risk of a crash.

Remedy: New Flyer will notify owners and will replace the brake pedal mounting plate and the Brake Valve Actuator (BVA), free of charge. The recall began on September 15, 2014. Owners may contact New Flyer customer service at 1-204-934-4876. New Flyer's number for this recall is R14-019.

Reported: 2015-06-01 (June 1, 2015) · Model years: 2013

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 C40LFR, XE40, XN35, and XN60, 2014 XD35, XDE40, and XT60, 2014-2015 XD60, and XT40, 2013-2014 XDE35, and XN40, and 2015 XDE60 transit buses. These vehicles have door controller assemblies that may have a software defect which can cause the rear passenger doors to open, without warning, when the bus accelerates from a stopped position.

Consequence: If the rear bus door opens while the bus is in motion, there is an increased risk of injury for the passengers.

Remedy: New Flyer will notify owners, and dealers will update the Door Controller Assembly software, free of charge. The recall began on June 24, 2015. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R15-006.

Reported: 2016-01-26 (January 26, 2016) · Model years: 2013

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.

Reported: 2016-04-19 (April 19, 2016) · Model years: 2013, 2014, 2015

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 C40LFR, XN35, 2014-2016 XD35, XD60, XDE40, 2015-2016 XD40, XDE60, 2014 XDE35, 2013-2015 XE40, 2013-2016 XN40, XN60, and 2014-2015 XT40, and XT60 transit buses. These buses have an Electric Transit Operator (ETO) controller that controls the bus door motor function which may have a software defect which can cause failure of the rear door guide roller linkage resulting in a bus' rear door opening unexpectedly while the bus is in motion.

Consequence: If the rear bus door opens unexpectedly while the bus is in motion, there is an increased risk of injury for the passengers.

Remedy: New Flyer will notify owners, and dealers will install a firmware upgrade, and replace the roller bracket plates, free of charge. The recall began on May 4, 2016. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R16-005.

Reported: 2021-04-07 (April 7, 2021) · Model years: 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021

New Flyer of America, Inc. (New Flyer) is recalling certain 2013-2021 XE40, 2019-2021 XE35, 2018-2021 XE60, 2016-2019 XHE40, and 2015 XHE60 vehicles. Firmware errors in the inverters may cause the electric drive system to shutdown.

Consequence: A sudden loss of power increases the risk of a crash.

Remedy: New Flyer will notify owners, and dealers will update firmware software, free of charge. The recall began on April 19, 2021. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R21-005.

Reported: 2022-12-20 (December 20, 2022) · Model years: 2013, 2014, 2015, 2016, 2017, 2018, 2019, 2020, 2021, 2022

New Flyer of America, Inc. (New Flyer) is recalling certain 2013-2022 XDE35, XDE40, XDE60, XE40, XN40, 2017-2022 XE60, 2014-2022 XT40 and XT60 transit buses equipped with a double tilt steering column. The steering column connection to the upper steering shaft may become loose.

Consequence: A loose steering shaft can cause a loss of steering, increasing the risk of a crash.

Remedy: Dealers will replace the steering column and shaft components, free of charge. Owner notification letters were mailed on February 1, 2023. Owners may contact New Flyer's customer service at 1-204-224-6706. New Flyer's number for this recall is R22-035.

Reported: 2025-08-29 (August 29, 2025) · Model years: 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025

New Flyer of America, Inc. (New Flyer) is recalling certain 2013, 2017-2025 XE40, 2019-2025 XE60, XE35, 2023-2025 XHE40, and 2024-2025 XHE60 buses. An inadequate weld on the high voltage battery busbar and incorrect software may cause the battery module to overheat.

Consequence: A battery module that overheats increases the risk of a fire.

Remedy: New Flyer will inspect and replace the battery module as necessary. New Flyer will also update the BMS software. All repairs will be performed free of charge. Owner notification letters were mailed October 6, 2025. Owners may contact New Flyer's customer service at 1-800-241-2947.

Reported: 2025-12-19 (December 19, 2025) · Model years: 2013, 2016, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025

New Flyer of America, Inc. (New Flyer) is recalling certain XD35, XDE35, XE35, XN35, XD40, XDE40, XE40, XHE40, XN40, XT40, XD60, XDE60, XE60, XN60, XT60, and XHE60 transit buses. Please refer to New Flyer's recall report for specific model year information. The antilock braking (ABS) and electronic stability control (ESC) module may lose communication and fail without illuminating the warning lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 121, "Air Brake Systems" and 136, "Electronic Stability Control Systems on Heavy Vehicles."

Consequence: An ABS or ESC warning light that fails to illuminate will not alert the driver to the loss of ABS or ESC, increasing the risk of a crash.

Remedy: New Flyer will update the software, free of charge. Owner notification letters were mailed February 17, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.

Reported: 2023-02-15 (February 15, 2023) · Model years: 2021, 2022, 2023

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XE35, 2021-2023 XE40, and 2021-2022 XE60 electric buses. One or more battery packs may accumulate liquid in the battery pack enclosure.

Consequence: The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.

Remedy: If liquid accumulation is found, the bus should not be operated, and should be parked outside and away from structures until repaired. Dealers will add four holes and automatic activating drain valves to each battery pack enclosure, free of charge. Owner notification letters were mailed May 3, 2023. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R23-002.

Reported: 2023-10-20 (October 20, 2023) · Model years: 2021, 2022

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XD35, 2022-2023 XD40, XD60, XN35, XN60, 2022 XDE35, and 2021-2022 XE40 transit buses. The Gross Axle Weight Rating (GAWR) and Gross Vehicle Weight Rating (GVWR) listed on the certification labels are incorrect, which can allow the vehicle to be overloaded. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 120, "Wheels and Rims - Other than Passenger Cars."

Consequence: An overloaded vehicle can increase the risk of a crash.

Remedy: New Flyer will provide and/or install new labels, free of charge. Owner notification letters were mailed November 9, 2023. Owners may contact New Flyer customer service at 1-800-241-2947.

Reported: 2023-12-22 (December 22, 2023) · Model years: 2021, 2022, 2023

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40 and 2023 XE60 battery electric transit buses. Due to a software error, unintended acceleration may occur during certain conditions.

Consequence: Unintended acceleration can increase the risk of a crash.

Remedy: New Flyer will update the vehicle software, free of charge. Owner notification letters were mailed February 13, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-023.

Reported: 2024-01-31 (January 31, 2024) · Model years: 2021, 2022, 2023

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40, 2021-2024 XE60, and 2023-2024 XHE40 vehicles. One or more drain valves may not activate as intended, which could allow battery packs to accumulate liquid in the battery pack enclosure.

Consequence: The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.

Remedy: New Flyer will remove the rubber washer from the affected drain valves, free of charge. Owner notification letters were mailed March 14, 2024. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R24-02. This recall is in addition to NHTSA recall number 23V-083. Certain vehicles are affected by both recalls and will need to have both remedies performed.

Reported: 2025-09-19 (September 19, 2025) · Model years: 2021, 2022, 2023, 2024, 2025

New Flyer of America, Inc. (New Flyer) is recalling certain 2019 XE35, 2021-2025 XE35, XE40, and XE60 transit buses. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity.

Consequence: A short circuit in a high voltage battery increases the risk of a fire.

Remedy: Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. New Flyer will replace the batteries, free of charge. This is a Phased campaign. Phase 1 will include 35 buses. New Flyer notified owners on 3/24/2026. Phase 2 will include 100 buses. New Flyer notified owners on 6/25/2026. Phase 3 will include 120 buses. New Flyer will notify owners on or about 9/16/2026. Phase 4 will include 120 buses. New Flyer will notify owners on or about 12/14/2026. Phase 5 will include 120 buses. New Flyer will notify owners on or about 3/15/2027. Phase 6 will include 80 buses. New Flyer will notify owners on or about 6/14/2027. Phase 7 will include 80 buses. New Flyer will notify owners on or about 9/27/2027. Interim owner notification letters explaining the safety risk were mailed November 12, 2025. A second letter will be sent once the remedy is available. Owners may contact New Flyer's customer service at 1-800-241-2947.

Reported: 2026-03-13 (March 13, 2026) · Model years: 2021, 2022, 2023, 2024, 2025, 2026

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2025 XE35, 2021-2026 XE40, 2023-2025 XE60, 2023-2026 XHE40, and 2024-2026 XHE60 transit buses equipped with Accelera ELFA 3 control systems V1 and V2. An inverter software error may cause unintended acceleration or deceleration in certain conditions.

Consequence: Unintended acceleration or deceleration can increase the risk of a crash.

Remedy: New Flyer will update the inverter software, free of charge. Owner notification letters were mailed April 30, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.

Reported: 2022-08-24 (August 24, 2022) · Model years: 2022

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XD40, XD60, XDE40, 2022 XN35, XE40, XN40, and 2021 XN60 transit buses. The steering gears may have been incorrectly assembled, which can cause the gear to fracture.

Consequence: A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.

Remedy: Dealers will inspect and replace the steering gear if required, free of charge. Owner notification letters were mailed on September 2, 2022. Owners may contact New Flyer's customer service at 1-204-224-6706. New Flyer's number for this recall is R22-026.

Reported: 2023-12-22 (December 22, 2023) · Model years: 2022

New Flyer of America, Inc. (New Flyer) is recalling certain 2022-2023 XD35, XD40, XN35, XN40, and 2023 XD60, XE35, XE40, and XN60 transit buses. Due to a software error, unintended acceleration may occur during certain conditions.

Consequence: Unintended acceleration can increase the risk of a crash.

Remedy: New Flyer will update the vehicle software, free of charge. Owner notification letters are expected to be mailed February 15, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-022.

Reported: 2026-05-01 (May 1, 2026) · Model years: 2022

New Flyer of America, Inc. (New Flyer) is recalling certain 2022 XE40 transit buses. The speedometer may not illuminate when the headlights are turned on. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 101, "Controls and Displays."

Consequence: An unlit speedometer cannot show the vehicle's speed, increasing the risk of a crash.

Remedy: New Flyer will update the software, free of charge. Owner notification letters are expected to be mailed June 15, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.