Data / Product recalls / New Flyer of America, Inc.
New Flyer of America, Inc.: 38 recalls from 2015 to 2026 (NHTSA)
New Flyer of America, Inc. is named in 38 recalls from 2015 to 2026: all from the NHTSA. The latest, on October 5, 2026, covers NEW Flyer XE40, XDE60, XDE40 (2013 to 2027) (693). Hazard: Without the illuminated reminder, the driver may fail to turn off the exterior lights when no longer needed. Source: NHTSA recall 26V644000.
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- Agencies
- National Highway Traffic Safety Administration
- First recall
- May 18, 2015
- Latest recall
- October 5, 2026
Recalls
Each recall is listed once, with the role this firm has in it. Roles: manufacturer (38).
| Date | Agency | Product | Hazard | Units | Remedy | Sold at | Role | Source |
|---|---|---|---|---|---|---|---|---|
| October 5, 2026 | NHTSA | NEW Flyer XE40, XDE60, XDE40 (2013 to 2027) | Without the illuminated reminder, the driver may fail to turn off the exterior lights when no longer needed. Hazard warning lights that remain activated unintentionally can confuse other drivers, increasing the risk of a crash. | 693 | New Flyer will update the software, free of charge. Owner notification letters are expected to be mailed November 20, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947. | Manufacturer | nhtsa.gov | |
| May 1, 2026 | NHTSA | NEW Flyer XE40 (2022) | An unlit speedometer cannot show the vehicle's speed, increasing the risk of a crash. | 4 | New Flyer will update the software, free of charge. Owner notification letters are expected to be mailed June 15, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947. | Manufacturer | nhtsa.gov | |
| March 13, 2026 | NHTSA | NEW Flyer XHE60, XE35, XHE40 (2021 to 2026) | Unintended acceleration or deceleration can increase the risk of a crash. | 1,196 | 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. | Manufacturer | nhtsa.gov | |
| December 19, 2025 | NHTSA | NEW Flyer XT60, XN35, XHE60 (2013 to 2026) | 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. | 6,673 | 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. | Manufacturer | nhtsa.gov | |
| September 19, 2025 | NHTSA | NEW Flyer XE35, XE60, XE40 (2019 to 2025) | A short circuit in a high voltage battery increases the risk of a fire. | 655 | 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... | Manufacturer | nhtsa.gov | |
| August 29, 2025 | NHTSA | NEW Flyer XE35, XHE40, XE40 (2013 to 2025) | A battery module that overheats increases the risk of a fire. | 1,170 | 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... | Manufacturer | nhtsa.gov | |
| August 22, 2025 | NHTSA | NEW Flyer Xcelsior (2012 to 2025) | An insufficient number, or incorrectly located, of emergency exits can prevent or delay passengers from exiting during an emergency, increasing their risk of injury. | 2,354 | New Flyer will mail instructions and necessary parts to add additional emergency egress windows, free of charge. Owner notification letters were mailed October 8, 2025. Owners may contact New Flyer's customer service at 1-800-241-2947. | Manufacturer | nhtsa.gov | |
| February 3, 2025 | NHTSA | NEW Flyer XDE60, XD60, XD40 (2023 to 2024) | A fuel leak in the presence of an ignition source increases the risk of a fire. An engine stall increases the risk of a crash. | 210 | Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed March 11, 2025. Owners may contact Cummins customer service at 1-800-286-6467 or New Flyer customer service at 1-800-241-2947. | Manufacturer | nhtsa.gov | |
| June 11, 2024 | NHTSA | NEW Flyer XD35, XD40, XD60 (2023) | A fuel leak in the presence of an ignition source increases the risk of a fire. Additionally, a lack of fuel can cause an engine stall, increasing the risk of a crash. | 27 | Cummins will replace the fuel filter hoses, free of charge. Owner notification letters are expected to be mailed July 21, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. | Manufacturer | nhtsa.gov | |
| January 31, 2024 | NHTSA | NEW Flyer XE35, XE60, XHE40 (2021 to 2024) | The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire. | 337 | 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... | Manufacturer | nhtsa.gov | |
| December 22, 2023 | NHTSA | NEW Flyer XE35, XN40, XN35 (2022 to 2023) | Unintended acceleration can increase the risk of a crash. | 211 | New Flyer will update the vehicle software, free of charge. Owner notification letters are expected to be mailed February 15, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is... | Manufacturer | nhtsa.gov | |
| December 22, 2023 | NHTSA | NEW Flyer XE35, XE40, XE60 (2021 to 2023) | Unintended acceleration can increase the risk of a crash. | 246 | New Flyer will update the vehicle software, free of charge. Owner notification letters were mailed February 13, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-023. | Manufacturer | nhtsa.gov | |
| October 26, 2023 | NHTSA | NEW Flyer XN40, XN35, XD35 (2019 to 2024) | A sudden loss of drive power can increase the risk of a crash. | 2,351 | New Flyer will work with the equipment manufacturer, Allison Transmission Inc., to inspect, and if necessary, tighten loose transmission yoke bolts, free of charge. Owner notification letters were mailed December 9, 2023. Owners may... | Manufacturer | nhtsa.gov | |
| October 20, 2023 | NHTSA | NEW Flyer XE40, XD35, XDE35 (2021 to 2023) | An overloaded vehicle can increase the risk of a crash. | 188 | New Flyer will provide and/or install new labels, free of charge. Owner notification letters were mailed November 9, 2023. Owners may contact New Flyer customer service at 1-800-241-2947. | Manufacturer | nhtsa.gov | |
| April 5, 2023 | NHTSA | NEW Flyer XDE60, XD60 (2023) | An ABS system that fails increases the risk of a crash. | 30 | New Flyer will update the ABS software and correct the wiring, free of charge. All vehicles have been repaired and therefore no owner letters will be sent. Owners may contact New Flyer customer service at 1-204-224-6706. | Manufacturer | nhtsa.gov | |
| February 15, 2023 | NHTSA | NEW Flyer XE60, XE35, XE40 (2021 to 2023) | The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire. | 219 | If liquid accumulation is found, the bus should not be operated, and should be parked outside and away from structures until repaired. Dealers will add four holes and automatic activating drain valves to each battery pack enclosure, free... | Manufacturer | nhtsa.gov | |
| December 20, 2022 | NHTSA | NEW Flyer XDE35, XN40, XT40 (2013 to 2022) | A loose steering shaft can cause a loss of steering, increasing the risk of a crash. | 746 | Dealers will replace the steering column and shaft components, free of charge. Owner notification letters were mailed on February 1, 2023. Owners may contact New Flyer's customer service at 1-204-224-6706. New Flyer's number for this... | Manufacturer | nhtsa.gov | |
| August 24, 2022 | NHTSA | NEW Flyer XD40, XE40, XN40 (2021 to 2022) | A fractured steering gear can cause a loss of steering control, increasing the risk of a crash. | 55 | Dealers will inspect and replace the steering gear if required, free of charge. Owner notification letters were mailed on September 2, 2022. Owners may contact New Flyer's customer service at 1-204-224-6706. New Flyer's number for this... | Manufacturer | nhtsa.gov | |
| July 28, 2021 | NHTSA | NEW Flyer XD35, XD40 (2021) | A fuel leak in the presence of an ignition source increases the risk of a fire. | 30 | Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed on August 3, 2021. Owners may contact New Flyer's customer service at 1-204-224-6706. | Manufacturer | nhtsa.gov | |
| July 14, 2021 | NHTSA | NEW Flyer XD35, XD40 (2021) | Exposure to high levels of ammonia can increase the risk of injury. | 28 | Cummins will recalibrate the engine, free of charge. Owner notification letters were mailed on July 23, 2021. Owners may contact New Flyer's customer service at 1-800-204-224-6706. New Flyer's number for this recall is R21-013. | Manufacturer | nhtsa.gov | |
| May 18, 2021 | NHTSA | NEW Flyer XD35, XD60, XD40 (2016 to 2021) | A fuel leak in the presence of an ignition source increases the risk of a fire. | 3,600 | New Flyer will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for... | Manufacturer | nhtsa.gov | |
| April 7, 2021 | NHTSA | NEW Flyer XE60, XE35, XE40 (2013 to 2021) | A sudden loss of power increases the risk of a crash. | 227 | New Flyer will notify owners, and dealers will update firmware software, free of charge. The recall began on April 19, 2021. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R21-005. | Manufacturer | nhtsa.gov | |
| August 6, 2020 | NHTSA | NEW Flyer XDE60, XDE40, XDE35 (2015 to 2016) | A loss of drive can disable the vehicle unexpectedly, increasing the risk of a crash. Additionally, offloading passengers to transfer them to another bus can increase the risk of injury. | 164 | New Flyer will notify owners, and Allison Transmissions will remove and replace the two C1 and C2 pressure switches on each hybrid drive motor, and also inspect and correct for debris accumulation in the associated pressure switch... | Manufacturer | nhtsa.gov | |
| February 15, 2019 | NHTSA | NEW Flyer XN40, XDE60, XD40 (2018 to 2019) | If the roof hatch glass shatters, glass particles could fall down onto passengers, increasing the risk of injury. | 172 | New Flyer has notified owners, and dealers will replace the tempered glass panel, free of charge. The recall began on March 6, 2019. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is... | Manufacturer | nhtsa.gov | |
| November 22, 2018 | NHTSA | NEW Flyer XN60, XN40, XD40 (2013 to 2017) | If the fire suppression system does not work as intended, it can increase the risk of injury in the event of a fire. | 463 | New Flyer has notified owners, and KTI will inspect the fire suppression systems and replace the electrical piston actuators, as necessary, free of charge. The recall began on November 29, 2018. Owners may contact New Flyer customer... | Manufacturer | nhtsa.gov | |
| September 12, 2018 | NHTSA | NEW Flyer XDE60, XDE40, XDE35 (2016 to 2018) | A loss of drive can disable the vehicle unexpectedly, increasing the risk of a crash. | 386 | New Flyer will notify owners, and Allison Transmission service centers will replace the C1 and C2 pressure switches, free of charge. The recall began on September 25, 2018. Owners may contact New Flyer customer service at 1-204-224-6706.... | Manufacturer | nhtsa.gov | |
| June 12, 2018 | NHTSA | NEW Flyer XN60, XDE60, XD60 (2014 to 2017) | Breakage of the guide pin can cause a reduction of braking ability and an increase in stopping distances, or a loss of tire pressure, increasing the risk of a crash. | 908 | New Flyer will notify owners, and dealers will install a bushing kit and reinstall the brake calipers, free of charge. The recall began June 29, 2018. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for... | Manufacturer | nhtsa.gov | |
| March 7, 2018 | NHTSA | NEW Flyer XDE40, XDE60, XDE35 (2016 to 2018) | Failure of the drive shaft end-caps would result in a loss of drive power, increasing the risk of a crash. | 979 | New Flyer will notify owners, and dealers will inspect the drive shaft slip yoke, replacing any drive shaft that has plastic end-caps on the slip yoke, free of charge. The recall began on March 22, 2018. Owners may contact New Flyer... | Manufacturer | nhtsa.gov | |
| January 9, 2018 | NHTSA | NEW Flyer XT60, XN40, XDE60 (2016 to 2017) | If the brake hose disconnects from the ABS modulator valve, there will be no brake force applied to either of the front axle brake assemblies, lengthening the needed braking distance and increasing the risk of a crash. | 283 | New Flyer will notify owners, and will reconnect the air hose using the proper tightness, free of charge. The recall began on January 11, 2018. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this... | Manufacturer | nhtsa.gov | |
| August 30, 2017 | NHTSA | NEW Flyer MD30, XD40, XN40 (2015 to 2017) | If the seat belt cannot be latched, the bus may be operated without the seat belt being used, increasing the risk of injury in the event of a crash. | 214 | New Flyer has notified owners and work with the supplier to replace the buckle housings, free of charge. The recall began September 15, 2017. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyers' number for this... | Manufacturer | nhtsa.gov | |
| March 1, 2017 | NHTSA | NEW Flyer GE40LF, D60LFR, D60LF (2005 to 2007) | Failure of the front axle beam can cause a loss of vehicle control, increasing the risk of a crash. | 2,357 | New Flyer will notify owners, and dealers will inspect the axle beams and determine a repair, as necessary, free of charge. The recall began on March 10, 2017. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's... | Manufacturer | nhtsa.gov | |
| September 20, 2016 | NHTSA | NEW Flyer XN60, XN40 (2016) | An unexpected release of CNG gas in the presence of an ignition source increases the risk of a fire. | 38 | New Flyer has notified owners, and dealers will install new a vent tubing system and replace the PRD, free of charge. The recall began September 28, 2016. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number... | Manufacturer | nhtsa.gov | |
| April 19, 2016 | NHTSA | NEW Flyer XN40, XN60, C40LFR (2013 to 2016) | If the rear bus door opens unexpectedly while the bus is in motion, there is an increased risk of injury for the passengers. | 1,897 | New Flyer will notify owners, and dealers will install a firmware upgrade, and replace the roller bracket plates, free of charge. The recall began on May 4, 2016. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's... | Manufacturer | nhtsa.gov | |
| January 26, 2016 | NHTSA | NEW Flyer, Nabi (2009 to 2015) | If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash, increasing their risk of injury. | 4,848 | New Flyer will notify owners instructing them to inspect their seats for missing welds. Recaro will supply replacement anchorage brackets and cover the labor to replace them if any welds are missing, free of charge. The recall began on... | Manufacturer | nhtsa.gov | |
| September 4, 2015 | NHTSA | NEW Flyer XN40, XN35, XD40 (2013 to 2015) | A loss of steering increases the risk of a crash. | 432 | New Flyer will notify owners, and dealers will inspect the vehicles to verify that the center link retaining clamp is properly torqued. Any components displaying play or movement will be replaced. These repairs will be performed free of... | Manufacturer | nhtsa.gov | |
| August 4, 2015 | NHTSA | Nabi 40LFW, 42BRT (2014 to 2015) | If the PRD does not activate in the event of a build up of pressure, the CNG tank may explode, increasing the risk of fire and injury. | 70 | New Flyer has notified owners, and Agility, supplier of the CNG system, will replace the PRDs, free of charge. The recall began on August 17, 2015. Owners may contact New Flyer customer service at 1-204-224-1251. New Flyer's number for... | Manufacturer | nhtsa.gov | |
| June 1, 2015 | NHTSA | NEW Flyer XDE35, XN40, XN60 (2013 to 2015) | If the rear bus door opens while the bus is in motion, there is an increased risk of injury for the passengers. | 1,147 | New Flyer will notify owners, and dealers will update the Door Controller Assembly software, free of charge. The recall began on June 24, 2015. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this... | Manufacturer | nhtsa.gov | |
| May 18, 2015 | NHTSA | NEW Flyer C40LF, C40LFR, C35LF (2008 to 2014) | If the engine oil comes into contact with hot surfaces, it can increase the risk of a vehicle fire. | 2,956 | Cummins will notify owners on behalf of New Flyer, and Cummins service centers will administer the repairs which include securing the ends of the 90-degree elbow and reprogramming the electronic control module (ECM) with software that can... | Manufacturer | nhtsa.gov |
By agency
| Agency | Recalls | Latest |
|---|---|---|
| National Highway Traffic Safety Administration | 38 | October 5, 2026 |
Categories
Where each agency publishes its recalls
Updated October 5, 2026. Read from National Highway Traffic Safety Administration recall data. Public domain (U.S. government work). Recalls are as the agencies published them: the CPSC, FDA (food enforcement reports) and NHTSA. A firm is one firm only when its exact name and country match; the CPSC and FDA print no firm ID. Stores are listed only when the agency's sold-at text names them, and an agency often adds that more stores sold the product. Categories are grouped by SpecStream from the words in the agency's title and product text. Free to reuse with credit to SpecStream under CC BY 4.0. Spot a wrong value? Write to [email protected] with the link to this page.