2024 NEW Flyer XE40 recalls

• High Voltage#2026118March 13, 2026

  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#2025711December 19, 2025

  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#2025495September 19, 2025

  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#2025444August 28, 2025

  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#2025430August 22, 2025

  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.

Canadian data updated August 24, 2026

• ELECTRICAL SYSTEM:PROPULSION SYSTEM:INVERTER#26V151000March 13, 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.

  Risk: 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.

• ELECTRONIC STABILITY CONTROL (ESC)#25V898000December 19, 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."

  Risk: 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.

• ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY#25V631000September 20, 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.

  Risk: 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.

• ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE#25V566000August 29, 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.

  Risk: 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.