01 / OFFICIAL CAMPAIGNS
2023 New Flyer XHE40 recall campaigns
NHTSA 26V151000
- Component
- ELECTRICAL SYSTEM
- Report received
- March 13, 2026
- Potential units
- 1,196campaign-wide
Defect and consequence
Defect: 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.
Why it matters: 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.
Owner notification: April 30, 2026 · Filing manufacturer: New Flyer of America, Inc.
NHTSA 25V898000
- Component
- ELECTRONIC STABILITY CONTROL (ESC), SERVICE BRAKES, AIR
- Report received
- December 19, 2025
- Potential units
- 6,673campaign-wide
Defect and consequence
Defect: 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.".
Why it matters: 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.
Owner notification: February 17, 2026 · Filing manufacturer: New Flyer of America, Inc.
NHTSA 25V566000
- Component
- ELECTRICAL SYSTEM
- Report received
- August 29, 2025
- Potential units
- 1,170campaign-wide
Defect and consequence
Defect: 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.
Why it matters: 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.
Owner notification: October 6, 2025 · Filing manufacturer: New Flyer of America, Inc.
NHTSA 24V056000
- Component
- ELECTRICAL SYSTEM
- Report received
- January 31, 2024
- Potential units
- 337campaign-wide
Defect and consequence
Defect: 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.
Why it matters: 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.
Owner notification: March 14, 2024 · Filing manufacturer: New Flyer of America, Inc.
02 / COMPONENT BREADTH