NEW Flyer XDE60 recalls

• Fuel System#2025045February 3, 2025

  117 units affected

  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 the engine to stall while driving. Note: This recall only affects buses equipped with certain L9 diesel engines. Safety Risk: A fuel leak can create the risk of a fire. Additionally, a sudden loss of engine power could increase the risk of a crash. Corrective Actions: New Flyer will notify owners by email and advise you to take your bus to a Cummins authorized service center to replace the remote fuel filter hoses.

• Fuel System#2021296May 18, 2021

  786 units affected

  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 create the risk of a fire. Corrective Actions: New Flyer will notify owners by mail and instruct you to take your bus to a Cummins authorized service center to inspect the fuel rail. If damage is found, the fuel rail and fuel lines will be replaced. If no damage is found, the fuel rail will be reassembled with new crush washers using a special tool.

• Powertrain#2020356August 4, 2020

  31 units affected

  Issue: On certain buses, the pressure switches on the hybrid drive system could fail. As a result, the bus could enter a reduced performance (limp) mode or there could be a loss of hybrid drive system power. Note: This is an expansion of Transport Canada Recall 2018-495 Safety Risk: A sudden loss of power to the wheels could increase the risk of a crash. Corrective Actions: New Flyer will notify owners by mail and request that you contact your Regional Product Support Manager. An Allison Transmission technician will inspect and replace the pressure switches. Certain buses also require an inspection of the valve body and internal passages of the pressure switch relay valve.

• Brakes#2018312June 13, 2018

  95 units affected

  On certain buses, there may be increased friction in the centre axle brake caliper guide pin due to a manufacturing defect. If undetected, this could cause the breakage of the guide pin bolt, irregular brake pad wear, and brake pad contact with the surface of the wheel. This could result in reduced braking force, a loss of tire pressure to an inner tire on the dual-wheeled center axle and possibly reduced parking brake functionality, increasing the risk of a crash causing injury and/or property damage. Correction: Customers will be supplied with a repair kit and directions to recondition both centre axle brake calipers.

• Powertrain#2018118March 8, 2018

  75 units affected

  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, which would cause loss of motive power while the vehicle is in motion, and increase the risk of a crash causing injury and/or damage to property. Correction: Owners will be provided instructions to inspect and replace the modified slip yokes.

• Brakes#2018013January 9, 2018

  133 units affected

  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 to separate, it would cause a loss of braking capability on the front axle, which could result in longer stopping distances, and would increase the risk of a crash causing injury and/or damage to property. Correction: Owners will be advised to disconnect the suspect front air brake hose connections, and reinstall the connections to the specified torque.

• Structure#2016164April 15, 2016

  159 units affected

  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 higher than required output torque from the ETO control module when the door is in a fully open position, which over time may result in a fracture of the rear door roller plate. If the roller plate fails there is a potential for the rear door to open inadvertently while the bus is in motion, which would increase the risk for injury to vehicle occupants, and/or result in damage to property. Correction: Dealers will reprogram the ETO control module, and replace both rear door roller plates with more robust versions.

• Brakes#2014371September 4, 2014

  274 units affected

  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. This misalignment could cause the brake valve actuator to become damaged, causing an increase in resistance when depressing the brake pedal, or brake drag when the pedal is released. This could increase vehicle stopping distances and increase the risk of a crash causing injury and/or damage to property. Correction: Owners will be sent repair instructions and revised parts.

• Electrical#2013177May 24, 2013

  69 units affected

  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-energized, which could injure someone working in the engine compartment. Correction: New Flyer will provide fleet operators with directives to inspect and replace both ignition switches (in the driver’s area, and in the engine compartment).

• Brakes#2012363October 24, 2012

  245 units affected

  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 and/or personal injury. Correction: Dealers will inspect and, if necessary, replace the brake chambers.

Canadian data updated August 24, 2026