Recall · 25V566000
New Flyer of America recalled 5 models over electrical system
1,170
Vehicles covered
5
Models
29
Model years
August 29, 2025
Filed with NHTSA
ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
- 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.
- What it can cause
- A battery module that overheats increases the risk of a fire.
- What the dealer does
- 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.
The repair is free, whatever the age or mileage of the vehicle, and whether or not you are the original owner.
Which vehicles
A recall reaches a range of VINs inside these model years, not every car built in them. Yours may not be covered even if it is listed here, and the only way to find out is NHTSA's own VIN lookup .
| Vehicle | Model years | Safety record |
|---|---|---|
| New FlyerXE35 | 2019 to 2025 | Not published here |
| New FlyerXE40 | 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024 and 2025 | Not published here |
| New FlyerXE60 | 2019 to 2025 | Not published here |
| New FlyerXHE40 | 2023 to 2025 | Not published here |
| New FlyerXHE60 | 2024 to 2025 | Not published here |
How this campaign compares
At 1,170 vehicles this is a bigger campaign than 60% of the 19,818 vehicle recalls filed since 1995 whose size NHTSA published. The middle campaign on file covers 472. It covers model years 2013 to 2025, so the oldest vehicles on it were 12 model years old when the defect was reported to NHTSA.
New Flyer vehicles have been recalled over the electrical system 9 times before this, most recently in January 2024 as 24V056000. That is not evidence the earlier repair failed.
The vehicles on this campaign carry 12 other recalls published here, the newest being: 26V279000 (electrical system), 26V151000 (electrical system), 25V898000 (electronic stability control (esc)), 25V631000 (electrical system).
Check your own car
A VIN check is the only answer for a specific vehicle, and it also shows every other open recall on it, which is usually the reason it is worth doing rather than reading one campaign.
Filed by New Flyer of America, Inc. with NHTSA on August 29, 2025 as campaign 25V566000. Every word of the defect, consequence and remedy above is NHTSA's published record of that filing, not a summary of it.
Compiled and maintained by guarledes . Data last checked 2025-08-29.
Independent developer and analyst