Recall · 25V631000
New Flyer of America recalled 3 models over electrical system
Park outside and away from buildings until repaired. NHTSA issues this where it considers the risk immediate, and it stands until the repair is done.
655
Vehicles covered
3
Models
16
Model years
September 20, 2025
Filed with NHTSA
ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY
- The defect
- New Flyer of America, Inc. (New Flyer) is recalling certain 2019 XE35, 2021-2025 XE35, XE40, and XE60 transit buses. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity.
- What it can cause
- A short circuit in a high voltage battery increases the risk of a fire.
- What the dealer does
- Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. New Flyer will replace the batteries, free of charge. This is a Phased campaign. Phase 1 will include 35 buses. New Flyer notified owners on 3/24/2026. Phase 2 will include 100 buses. New Flyer will notify owners on or about 6/15/2026. Phase 3 will include 120 buses. New Flyer will notify owners on or about 9/16/2026. Phase 4 will include 120 buses. New Flyer will notify owners on or about 12/14/2026. Phase 5 will include 120 buses. New Flyer will notify owners on or about 3/15/2027. Phase 6 will include 80 buses. New Flyer will notify owners on or about 6/14/2027. Phase 7 will include 80 buses. New Flyer will notify owners on or about 9/27/2027. Interim owner notification letters explaining the safety risk were mailed November 12, 2025. A second letter will be sent once the remedy is available. 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, 2021, 2022, 2023, 2024 and 2025 | Not published here |
| New FlyerXE40 | 2021 to 2025 | Not published here |
| New FlyerXE60 | 2021 to 2025 | Not published here |
How this campaign compares
At 655 vehicles this is a bigger campaign than 53% of the 19,818 vehicle recalls filed since 1995 whose size NHTSA published. The middle campaign on file covers 472. It covers model years 2019 to 2025, so the oldest vehicles on it were 6 model years old when the defect was reported to NHTSA.
New Flyer vehicles have been recalled over the electrical system 10 times before this, most recently in August 2025 as 25V566000. 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)), 25V566000 (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 September 20, 2025 as campaign 25V631000. 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 2025-09-20.
Independent developer and analyst