RECALLS — NEW FLYER XE40
NEW Flyer XE40 recalls
NEW Flyer XE40 model years 2013–2026 covered by at least one recall campaign. Pick a year to see the Canadian and U.S. campaigns side by side.
Choose a model year
U.S. NHTSA campaigns are listed on each year page, where they are queried live by model year. The Canadian list below covers every year together.
Transport Canada recalls
09- High Voltage#2026118
392 units affected
Issue: Under certain conditions, a software problem could cause the inverter not to work properly. If this happens, the bus could accelerate unexpectedly or there could be a sudden loss of power to the wheels. Note: This recall only affects certain electric transit buses equipped with a V1 or V2 Accelera Safety Risk: A bus that accelerates suddenly and/or a loss of power to the wheels could increase the risk of a crash. Corrective Actions: New Flyer will notify owners by email and provide you with instructions for how to update the inverter software. Alternatively, you may contact New Flyer to arrange for a service technician to complete the repairs.
- Lights And Instruments#2025711
466 units affected
Issue: 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. Safety Risk: A warning light that doesn't turn on could cause you not to be aware of a problem with the ABS. This could increase the risk of a crash. Corrective Actions: New Flyer will notify owners in writing and provide you with instructions for how to update the vehicle software. Alternatively, you may contact New Flyer to arrange for a service team to perform the repairs.
- High Voltage#2025495
12 units affected
Issue: On certain electric transit buses, under certain conditions, the high voltage battery cells could short circuit and/or fail. Note: Certain buses repaired under Transport Canada recall no.2025-444 also require this repair. Safety Risk: A short circuit in the high-voltage battery can create a fire risk, even while the vehicle is parked and turned off. Corrective Actions: New Flyer will notify owners by email. As an interim repair, a technician will install an advanced diagnostic software that will monitor the high-voltage battery and warn you if it detects a problem. If you see this warning, you should contact New Flyer. To reduce the safety risk, New Flyer recommends that you set the maximum charge setting of your bus at 75% until the interim repair is completed. The final corrective actions for this recall are under development.
- High Voltage#2025444
107 units affected
Issue: On certain electric buses, a bus bar inside the high-voltage battery may not have been welded properly. As a result, the bus bar could overheat and/or there could be electrical arcing (sparks). Safety Risk: A bus bar that overheats and/or electrical arcing can create the risk of a fire. Corrective Actions: New Flyer will notify owners by email and arrange for a service technician to update the battery management system (BMS) software or provide you with instructions for how to update the BMS software. The software will monitor the high-voltage battery and warn you if it detects a problem. If you see this warning, you should contact New Flyer to arrange for a service technician to inspect and, if necessary, replace the high-voltage battery module(s).
- Structure#2025430
312 units affected
Issue: 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. Safety Risk: Missing or incorrectly located emergency exits could slow your exit from the bus in an emergency. This could increase the risk of injury. Corrective Actions: New Flyer will notify owners in writing. The corrective actions for this recall are under development.
- Electrical#2024055
6 units affected
Issue: On a small number of transit buses, the recall repairs completed during recall R23-002 (Transport Canada recall number 2023-073) may not be effective. As a result, a second repair is required. On a small number of transit buses, the automatic drain valves inside the energy storage system (ESS) may not work properly. As a result, liquid could build up inside the ESS and cause a short circuit. Safety Risk: A short circuit can create the risk of a fire. Corrective Actions: New Flyer will notify owners by email and provide you with instructions for how to remove the rubber washer from the drain valves. Alternatively, New Flyer will arrange for a service team to complete the recall repairs. New Flyer advises that if a yellow "LOW COOLANT" or a red "CRITICALLY LOW COOLANT" warning displays on the dash, all ESSs must be inspected immediately.
- Seats And Restraints#2016031
144 units affected
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 structure in the event of a crash, which would increase the risk of injury. Correction: Dealers will inspect for missing welds and if required replace the J-brackets.
- Structure#2015215
128 units affected
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 operational status from the vehicle multiplex system. If the driver were to initiate the doors open option as the bus accelerates from a stop, this could allow the passenger doors to reopen. If this were to occur while the vehicle is in motion, an occupant could fall from the vehicle and sustain injuries. Correction: Dealers will update the vehicle software.
- Brakes#2014371
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.
Canadian data updated August 24, 2026
Does this recall apply to my vehicle?
Matched by make, model, and model year. Many recalls affect only specific VIN ranges — confirm with your dealer using your full VIN.
What to do
Recall repairs are free at a franchised dealer in both countries. To confirm a recall applies to your specific vehicle, contact your manufacturer or dealer with your full VIN, or use the official channel:
- NHTSA recall lookup (search by VIN) — U.S. National Highway Traffic Safety Administration
- Defects and recalls database — Transport Canada