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.
NHTSA's own wording · initiated by MFR
Vehicles covered
| Model | Model years |
|---|---|
| NEW Flyer XE35 | 2019, 2020, 2021, 2022, 2023, 2024, 2025 |
| NEW Flyer XE40 | 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025 |
| NEW Flyer XE60 | 2019, 2020, 2021, 2022, 2023, 2024, 2025 |
| NEW Flyer XHE40 | 2023, 2024, 2025 |
| NEW Flyer XHE60 | 2024, 2025 |
Components: ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY | ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| NEW Flyer XE35 | 2019 | 0 | 4 |
| NEW Flyer XE35 | 2020 | 0 | 4 |
| NEW Flyer XE35 | 2021 | 0 | 9 |
| NEW Flyer XE35 | 2022 | 0 | 8 |
| NEW Flyer XE35 | 2023 | 0 | 8 |
| NEW Flyer XE35 | 2024 | 0 | 5 |
| NEW Flyer XE35 | 2025 | 0 | 5 |
| NEW Flyer XE40 | 2013 | 0 | 9 |
| NEW Flyer XE40 | 2017 | 0 | 5 |
| NEW Flyer XE40 | 2018 | 0 | 5 |
| NEW Flyer XE40 | 2019 | 0 | 5 |
| NEW Flyer XE40 | 2020 | 0 | 5 |
| NEW Flyer XE40 | 2021 | 0 | 11 |
| NEW Flyer XE40 | 2022 | 0 | 13 |
| NEW Flyer XE40 | 2023 | 0 | 8 |
| NEW Flyer XE40 | 2024 | 0 | 5 |
| NEW Flyer XE40 | 2025 | 0 | 5 |
| NEW Flyer XE60 | 2019 | 0 | 6 |
| NEW Flyer XE60 | 2020 | 0 | 5 |
| NEW Flyer XE60 | 2021 | 0 | 8 |
| NEW Flyer XE60 | 2022 | 0 | 7 |
| NEW Flyer XE60 | 2023 | 0 | 7 |
| NEW Flyer XE60 | 2024 | 0 | 6 |
| NEW Flyer XE60 | 2025 | 0 | 5 |
| NEW Flyer XHE40 | 2023 | 0 | 4 |
| NEW Flyer XHE40 | 2024 | 0 | 5 |
| NEW Flyer XHE40 | 2025 | 0 | 4 |
| NEW Flyer XHE60 | 2024 | 0 | 4 |
| NEW Flyer XHE60 | 2025 | 0 | 4 |
Other electrical system recalls in 2025
148 of the 891 recall campaigns reported to NHTSA in 2025 concerned the electrical system; New Flyer of America, Inc. filed 22 campaigns in all.
| 25V914000 31 Dec 2025 | Braun Industries, Inc. |
| 25V906000 23 Dec 2025 | BMW of North America, LLC |
| 25V911000 23 Dec 2025 | Honda (American Honda Motor Co.) |
| 25V905000 23 Dec 2025 | Tiffin Motorhomes, Inc. |
| 25V897000 19 Dec 2025 | Blue Bird Body Company |
| 25V895000 19 Dec 2025 | Coach and Equipment Mfg. Corp. |
| 25V894000 19 Dec 2025 | Mercedes-Benz USA, LLC |
| 25V886000 18 Dec 2025 | Ford Motor Company |
NHTSA recalls (public domain) · all recalls of 2025