2013–2025 New Flyer XE40 & 2019–2025 New Flyer XE35 + 3 more recall: electrical system
⚠️ What's wrong
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.
💥 The risk
A battery module that overheats increases the risk of a fire.
🔧 The fix
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.
Is the fix free? Yes. Safety recall repairs are free at any authorized dealer under federal law, including parts and labor. (Vehicles more than 15 years old when the recall was announced can be excluded, but most manufacturers still fix them.)
- NHTSA campaign
- 25V566000
- Manufacturer
- New Flyer of America, Inc.
- Vehicles affected
- 1,170
- Component
- ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY; ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
- Owner phone
- 1-800-241-2947
- NHTSA hotline
- 1-888-327-4236
- Owner letters mailed
- Oct 6, 2025
- Recall started by
- MFR