RECALLS — NEW FLYER XN40
NEW Flyer XN40 recalls
NEW Flyer XN40 model years 2012–2023 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- Label#2024237
627 units affected
Issue: On certain transit buses, the compliance label lists incorrect information for the compressed natural gas (CNG) system. This includes the total water volume, the system check date and the "do not fill after" date. Additionally, the labels may be missing information in French. As a result, the incorrect or missing information could cause confusion and lead you to fill the system beyond the stated capacity and/or fill date. Note: This recall only affects buses equipped with a compressed natural gas (CNG) engine. Safety Risk: A CNG system that is filled beyond its capacity and/or after the fill date could increase the risk of injury. Corrective Actions: New Flyer will notify owners by email and provide them with new labels and instructions for how to install them.
- Steering#2022732
131 units affected
Issue: On certain buses, the pinch bolt connecting the upper and lower steering column shafts may loosen. If this happens, you could lose steering control. Note: This recall only affects buses with a double tilt steering column. Safety Risk: A loss of steering control could create a risk of a crash. Corrective Actions: New Flyer will notify owners by mail and provide you with instructions for how to inspect the steering column, and replace it if necessary.
- Powertrain#2018118
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.
- Structure#2016164
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.
- Suspension#2015392
26 units affected
On certain buses, a tie rod end retaining clamp from the center link tube assembly on the front axle may have not have been torqued to specification during front end alignment adjustment by the vehicle manufacturer. This could result in the tie rod end separating, which could result in a loss of steering control, increasing the risk of a crash causing injury and/or damage to property. Correction: Dealers will inspect the retaining clamp for proper torque. If any wear or movement of the cross link assembly is evident, the damaged components will be replaced.
- 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.
- Engine#2015212
88 units affected
On certain vehicles equipped with Cummins Westport ISL-G engines, excessive engine crankcase pressure could cause the vent tube assembly elbow to detach from the breather. This could allow engine oil to come in contact with hot surfaces, increasing the risk of fire resulting in injury and/or damage to property. Correction: Dealers will install clamps at both ends of the elbow of the breather tube assembly and reprogram the Electronic Control Module (ECM) to improve diagnostic capabilities.
- 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.
- Engine#2014065
29 units affected
On certain vehicles equipped with Cummins compressed natural gas engines, incorrect engine ECU programming could cause the exhaust system temperature to become elevated during cold weather operation. This could also cause flames to be emitted from the exhaust. As a result, nearby combustible material could be ignited, increasing the risk of a fire, injury and/or damage to property. Correction: Authorized Cummins service facilities will update software programming.
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