New Flyer of America, Inc.: Electrical System › Propulsion System › Traction Battery
New Flyer of America, Inc. reported this defect to federal regulators on Aug 29, 2025 and put the number of vehicles at risk at 1,170. The repair is free for as long as the recall stands.
The 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.
The risk
A battery module that overheats increases the risk of a fire.
The 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.
29 model years covered
Newest first| Vehicle | Complaints | Recalls | Fires | Crashes |
|---|---|---|---|---|
| 2025 New Flyer XE35 | 0 | 5 | 0 | 0 |
| 2025 New Flyer XE40 | 0 | 5 | 0 | 0 |
| 2025 New Flyer XE60 | 0 | 5 | 0 | 0 |
| 2025 New Flyer XHE40 | 0 | 4 | 0 | 0 |
| 2025 New Flyer XHE60 | 0 | 4 | 0 | 0 |
| 2024 New Flyer XE35 | 0 | 5 | 0 | 0 |
| 2024 New Flyer XE40 | 0 | 5 | 0 | 0 |
| 2024 New Flyer XE60 | 0 | 6 | 0 | 0 |
| 2024 New Flyer XHE40 | 0 | 5 | 0 | 0 |
| 2024 New Flyer XHE60 | 0 | 4 | 0 | 0 |
| 2023 New Flyer XE35 | 0 | 8 | 0 | 0 |
| 2023 New Flyer XE40 | 0 | 8 | 0 | 0 |
| 2023 New Flyer XE60 | 0 | 7 | 0 | 0 |
| 2023 New Flyer XHE40 | 0 | 4 | 0 | 0 |
| 2022 New Flyer XE35 | 0 | 8 | 0 | 0 |
| 2022 New Flyer XE40 | 0 | 13 | 0 | 0 |
| 2022 New Flyer XE60 | 0 | 7 | 0 | 0 |
| 2021 New Flyer XE35 | 0 | 9 | 0 | 0 |
| 2021 New Flyer XE40 | 0 | 11 | 0 | 0 |
| 2021 New Flyer XE60 | 0 | 8 | 0 | 0 |
| 2020 New Flyer XE35 | 0 | 4 | 0 | 0 |
| 2020 New Flyer XE40 | 0 | 5 | 0 | 0 |
| 2020 New Flyer XE60 | 0 | 5 | 0 | 0 |
| 2019 New Flyer XE35 | 0 | 4 | 0 | 0 |
| 2019 New Flyer XE40 | 0 | 5 | 0 | 0 |
| 2019 New Flyer XE60 | 0 | 6 | 0 | 0 |
| 2018 New Flyer XE40 | 0 | 5 | 0 | 0 |
| 2017 New Flyer XE40 | 0 | 5 | 0 | 0 |
| 2013 New Flyer XE40 | 0 | 9 | 0 | 0 |
What this page is, and what to do next
A recall is not an opinion. It is a Part 573 report a manufacturer is required by federal law to file once it decides a defect poses an unreasonable risk to safety, and it commits them to repairing the vehicle at no cost to the owner. The three passages above are the manufacturer’s own wording as published by NHTSA.
This page describes the campaign. It cannot tell you whether one particular car has already been through the shop — that is tracked by VIN, and only the manufacturer knows it. Check yours at nhtsa.gov/recalls or with a franchised dealer, quoting campaign number 25V566000.
Full record for the 2025 New Flyer XE35 → · Recalls carrying a do-not-drive advisory → · Where this data comes from →