New Flyer recall: Electrical system
What is 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.
What could happen
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.
Vehicles covered
- New Flyer Xe35 2019–2025
- New Flyer Xe40 2013, 2017–2025
- New Flyer Xe60 2019–2025
- New Flyer Xhe40 2023–2025
- New Flyer Xhe60 2024–2025
Facts
- NHTSA recall number
- 25V566000
- Type
- Vehicle
- Filed by
- New Flyer Of America, Inc.
- Reported to NHTSA
- Aug 29, 2025
- Owners notified
- Oct 6, 2025
- Vehicles or items affected
- 1,170
- Started by
- The manufacturer
- Built
- –
- Part
- Electrical system › Propulsion system › Traction battery; Electrical system › Propulsion system › Traction battery › Management system/energy control module (bms/becm) › Software
Other recalls for the same vehicles
- New Flyer recall: Electrical system Oct 5, 2026
- New Flyer recall: Electrical system Mar 13, 2026
- New Flyer recall: Electronic stability control (esc) Dec 19, 2025
- New Flyer recall: Electrical system Apr 7, 2021
- New Flyer recall: Electrical system Sep 19, 2025
- New Flyer recall: Electrical system Jan 31, 2024
To check one car, enter its 17-character VIN on the official NHTSA page: a recall may cover only some vehicles of a model year.
Recall data: National Highway Traffic Safety Administration (NHTSA). Nebula is not affiliated with or endorsed by NHTSA.