2021 New Flyer XD40

Routine

No owner complaints are on file for this vehicle. It has been recalled 6 times.

6 safety recalls

Part 573 reports
Electronic Stability Control (esc)25V898000
Filed Dec 19, 20256,673 vehiclesNew Flyer Of America, Inc.

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."

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.

Power Train › Driveline › Driveshaft23V722000
Filed Oct 26, 20232,351 vehiclesNew Flyer Of America, Inc.

Defect. New Flyer of America, Inc. (New Flyer) is recalling certain 2019-2024 XD35, XD40, XN35, and XN40 transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.

Risk. A sudden loss of drive power can increase the risk of a crash.

Remedy. 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 contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-20.

Steering22V637000
Filed Aug 24, 202255 vehiclesNew Flyer Of America, Inc.

Defect. New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XD40, XD60, XDE40, 2022 XN35, XE40, XN40, and 2021 XN60 transit buses. The steering gears may have been incorrectly assembled, which can cause the gear to fracture.

Risk. A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.

Remedy. 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 recall is R22-026.

Fuel System, Diesel › Delivery › Hoses, Lines/Piping, and Fittings21V576000
Filed Jul 28, 202130 vehiclesNew Flyer Of America, Inc.

Defect. New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD40 and XD35 vehicles equipped with Cummins L9 Diesel engines that have remote Stage 2 fuel filters and pressurized hoses. A fuel leak may occur from the fuel hose between the fuel pump and the remote fuel filter head.

Risk. A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy. 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.

Engine and Engine Cooling › Exhaust System › Manifold/Header/Muffler/Tail Pipe21V532000
Filed Jul 14, 202128 vehiclesNew Flyer Of America, Inc.

Defect. New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD35 and XD40 vehicles equipped with 2021 Model Year Cummins L9 Diesel Engines. The engine calibration software's management of the injection of Diesel Exhaust Fluid can allow excessive ammonia to be emitted from tailpipe exhaust.

Risk. Exposure to high levels of ammonia can increase the risk of injury.

Remedy. 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.

Fuel System, Diesel › Fuel Injection System › Fuel Rail21V365000
Filed May 18, 20213,600 vehiclesNew Flyer Of America, Inc.

Defect. New Flyer of America, Inc. (New Flyer) is recalling certain 2017-2021 XD40, XD35, 2016-2021 XD60, 2017 XDE35, 2016-2020 XDE40, XDE60 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.

Risk. A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy. 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 this recall is R21-008.

Across model years

Worst on record: 2026
YearComplaintsRecallsFiresDeathsAssessment
20260100Routine
20250100Routine
20240300Routine
20230500Routine
20220500Routine
2021 — this page0600Routine
20200300Routine
20190300Routine
20180300Routine
20170500Routine
20160300Routine
20150500Routine
20140400Routine
20130300Routine
20120200Routine
20110200Routine
20100100Routine

Compare every XD40 year →

Reading this record

No unusual pattern of severe incidents in the complaint record.

Complaint counts track how many cars were sold and how long they have been on the road as much as they track quality. A common model from 2013 has had a decade to accumulate reports; a rare one from last year has not. The signal worth weighing is in the severity columns, in whether the same component keeps appearing, and in whether the manufacturer eventually opened a recall for it.

Recall repairs are free for as long as the recall stands. Check whether a specific car still has open work at NHTSA's VIN lookup.

Most recent recall on file: Dec 19, 2025. Source: NHTSA Office of Defects Investigation.