New Flyer XD35 recalls

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain XD35, XDE35, XE35, XN35, XD40, XDE40, XE40, XHE40, XN40, XT40, XD60, XDE60, XE60, XN60, XT60, and XHE60 transit buses. Please refer to New Flyer's recall report for specific model year information. The antilock braking (ABS) and electronic stability control (ESC) module may lose communication and fail without illuminating the warning lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 121, "Air Brake Systems" and 136, "Electronic Stability Control Systems on Heavy Vehicles."

Risk

An ABS or ESC warning light that fails to illuminate will not alert the driver to the loss of ABS or ESC, increasing the risk of a crash.

Remedy

New Flyer will update the software, free of charge. Owner notification letters were mailed February 17, 2026. Owners may contact New Flyer's customer service at 1‑800‑241‑2947.

Recall number 25V898000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2023-2024 XDE60, 2024 XD35, XD40, and XD60 transit buses equipped with Cummins L9 diesel engines. The remote fuel filter hoses may separate from the fitting, causing a fuel leak and an engine stall.

Risk

A fuel leak in the presence of an ignition source increases the risk of a fire. An engine stall increases the risk of a crash.

Remedy

Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed March 11, 2025. Owners may contact Cummins customer service at 1‑800‑286‑6467 or New Flyer customer service at 1‑800‑241‑2947.

Recall number 25V053000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2023 XD35, XD40, and XD60 vehicles equipped with certain Cummins L9 diesel engines. The remote fuel filter hoses may become separated from the fitting, which can result in a fuel leak and a lack of fuel supply to the engine.

Risk

A fuel leak in the presence of an ignition source increases the risk of a fire. Additionally, a lack of fuel can cause an engine stall, increasing the risk of a crash.

Remedy

Cummins will replace the fuel filter hoses, free of charge. Owner notification letters are expected to be mailed July 21, 2024. Owners may contact New Flyer customer service at 1‑800‑241‑2947.

Recall number 24V425000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2022-2023 XD35, XD40, XN35, XN40, and 2023 XD60, XE35, XE40, and XN60 transit buses. Due to a software error, unintended acceleration may occur during certain conditions.

Risk

Unintended acceleration can increase the risk of a crash.

Remedy

New Flyer will update the vehicle software, free of charge. Owner notification letters are expected to be mailed February 15, 2024. Owners may contact New Flyer customer service at 1‑800‑241‑2947. New Flyer's number for this recall is R23-022.

Recall number 23V898000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2019-2024 XD35, XD40, XN35, and XN40 transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.

Risk

A sudden loss of drive power can increase the risk of a crash.

Remedy

New Flyer will work with the equipment manufacturer, Allison Transmission Inc., to inspect, and if necessary, tighten loose transmission yoke bolts, free of charge. Owner notification letters were mailed December 9, 2023. Owners may contact New Flyer customer service at 1‑800‑241‑2947. New Flyer's number for this recall is R23-20.

Recall number 23V722000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XD35, 2022-2023 XD40, XD60, XN35, XN60, 2022 XDE35, and 2021-2022 XE40 transit buses. The Gross Axle Weight Rating (GAWR) and Gross Vehicle Weight Rating (GVWR) listed on the certification labels are incorrect, which can allow the vehicle to be overloaded. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 120, "Wheels and Rims - Other than Passenger Cars."

Risk

An overloaded vehicle can increase the risk of a crash.

Remedy

New Flyer will provide and/or install new labels, free of charge. Owner notification letters were mailed November 9, 2023. Owners may contact New Flyer customer service at 1‑800‑241‑2947.

Recall number 23V711000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD40 and XD35 vehicles equipped with Cummins L9 Diesel engines that have remote Stage 2 fuel filters and pressurized hoses. A fuel leak may occur from the fuel hose between the fuel pump and the remote fuel filter head.

Risk

A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy

Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed on August 3, 2021. Owners may contact New Flyer's customer service at 1‑204‑224‑6706.

Recall number 21V576000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD35 and XD40 vehicles equipped with 2021 Model Year Cummins L9 Diesel Engines. The engine calibration software's management of the injection of Diesel Exhaust Fluid can allow excessive ammonia to be emitted from tailpipe exhaust.

Risk

Exposure to high levels of ammonia can increase the risk of injury.

Remedy

Cummins will recalibrate the engine, free of charge. Owner notification letters were mailed on July 23, 2021. Owners may contact New Flyer's customer service at 1-800-204‑224‑6706. New Flyer's number for this recall is R21-013.

Recall number 21V532000 · Recall details

What is wrong

New Flyer of America, Inc. (New Flyer) is recalling certain 2017-2021 XD40, XD35, 2016-2021 XD60, 2017 XDE35, 2016-2020 XDE40, XDE60 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.

Risk

A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy

New Flyer will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R21-008.

Recall number 21V365000 · Recall details

What is wrong

New Flyer Industries Ltd. (New Flyer) is recalling certain 2015-2016 MD30, 2016 MD35, 2017 XD35, XD60, XDE35, XDE40, XDE60, XN35 and 2016-2017 XD40 and XN40 transit buses, equipped with certain Recaro Commercial Bus Driver Seats (models Ergo R, Ergo D, AM71, AM72 and AM80). The seat belt buckle may be stuck in the locked position, preventing the seat belt tongue from being able to be inserted and locked.

Risk

If the seat belt cannot be latched, the bus may be operated without the seat belt being used, increasing the risk of injury in the event of a crash.

Remedy

New Flyer has notified owners and work with the supplier to replace the buckle housings, free of charge. The recall began September 15, 2017. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyers' number for this recall is R17-017.

Recall number 17V539000 · Recall details

What is wrong

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 C40LFR, XN35, 2014-2016 XD35, XD60, XDE40, 2015-2016 XD40, XDE60, 2014 XDE35, 2013-2015 XE40, 2013-2016 XN40, XN60, and 2014-2015 XT40, and XT60 transit buses. These buses have an Electric Transit Operator (ETO) controller that controls the bus door motor function which may have a software defect which can cause failure of the rear door guide roller linkage resulting in a bus' rear door opening unexpectedly while the bus is in motion.

Risk

If the rear bus door opens unexpectedly while the bus is in motion, there is an increased risk of injury for the passengers.

Remedy

New Flyer will notify owners, and dealers will install a firmware upgrade, and replace the roller bracket plates, free of charge. The recall began on May 4, 2016. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R16-005.

Recall number 16V223000 · Recall details

What is wrong

New Flyer Industries, Ltd. (New Flyer) is recalling certain model year 2015 New Flyer MD30, 2012 C35LFR, 2010-2011 D35LFR, NABI 35LFW, 2011 D40LFR, 2010-2012 D60LFR and NABI 31LFW, 2010 C40LF, DE35LF, D40LF, DE40LFA, DE60LFA, GE35LFR and GE40LF, 2009 DE60LF and GE40LFR, 2010-2013 C40LFR, DE60LFR, NABI 416 and NABI 60BRT, 2010-2015 XD35, XDE40, NABI 40LFW and 42BRT, 2011-2015 XD40 and XN40, 2013-2015 XD60, XDE60 and XN35, 2010-2014 XDE35, 2013 XE40, 2012-2015 XN60, equipped with certain Recaro Ergo-M Commercial Bus Driver Seats. The affected seats have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.

Risk

If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash, increasing their risk of injury.

Remedy

New Flyer will notify owners instructing them to inspect their seats for missing welds. Recaro will supply replacement anchorage brackets and cover the labor to replace them if any welds are missing, free of charge. The recall began on February 4, 2016. Owners may contact New Flyer customer service at 1‑204‑224‑6706, or Recaro customer service at 1‑800‑873‑2276. New Flyer's number for this recall is R16-001.

Recall number 16V038000 · Recall details

What is wrong

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 C40LFR, XE40, XN35, and XN60, 2014 XD35, XDE40, and XT60, 2014-2015 XD60, and XT40, 2013-2014 XDE35, and XN40, and 2015 XDE60 transit buses. These vehicles have door controller assemblies that may have a software defect which can cause the rear passenger doors to open, without warning, when the bus accelerates from a stopped position.

Risk

If the rear bus door opens while the bus is in motion, there is an increased risk of injury for the passengers.

Remedy

New Flyer will notify owners, and dealers will update the Door Controller Assembly software, free of charge. The recall began on June 24, 2015. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R15-006.

Recall number 15V333000 · Recall details

What is wrong

New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 XD35, XDE35, XE40, and 2013-2014 XD40, XD60, XDE40, XDE60, XN35, XN40, and XN60 transit buses. During installation, the Brake Pedal Mounting Plate may have been clamped between the Brake Pedal Assembly and the Brake Valve Actuator (BVA) resulting in a misalignment and binding of the internal piston in the BVA.

Risk

The binding of the piston may result in increased resistance while applying the brakes and the potential for brake drag once the brake pedal is released. These conditions increase the risk of a crash.

Remedy

New Flyer will notify owners and will replace the brake pedal mounting plate and the Brake Valve Actuator (BVA), free of charge. The recall began on September 15, 2014. Owners may contact New Flyer customer service at 1‑204‑934‑4876. New Flyer's number for this recall is R14-019.

Recall number 14V532000 · Recall details

What is wrong

New Flyer Industries is recalling certain model year 2012 XD35 and XD40, model year 2013 XD60, XDE40 and XDE60 and model year 2012-2013 XN40 and XN60 transit buses. In the affected buses, the push-to-start button switch may have a weak return spring, allowing the engine to start unexpectedly.

Risk

If the engine starts without warning, there is an increased risk for injury to persons working on or near the engine.

Remedy

New Flyer will notify owners, and dealers will inspect and replace the switches free of charge. The recall began June 19, 2013. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's recall number is R13-014.

Recall number 13V221000 · Recall details

What is wrong

New Flyer is recalling certain model year 2010-2012 transit buses, models C40LF, C40LFR, D35LFR, D40LFR, D60LFR, XD35, XD40, XDE35, XDE40, and XN40. Air pressure may leak from the parking brake chambers causing the parking brakes to drag while the vehicle is driven.

Risk

If the brakes drag, they may overheat, possibly resulting in a fire.

Remedy

New Flyer will notify the owners and the affected brake chambers will be replaced, free of charge. The recall began on November 13, 2012. Owners may contact New Flyer at 1‑204‑224‑6706 for more information.

Recall number 12V518000 · Recall details

What is wrong

New flyer is recalling certain model years 2009-2012 xde40, model years 2010-2011 models xd35 and xde35, model year 2010 xd40, and model year 2011 xn40 transit buses, manufactured from january 2010, through december 2011, and equipped with a parker-hannifin (vansco) instrument panel. The programming of the instrument panel is such that if multiple error messages are received by the instrument panel from the vehicle powertrain, the “check engine” and/or “stop engine” indicator lamps on the dash may not illuminate and the engine may enter a safety or shutdown mode of operation.

Risk

Engine shutdown would result in loss of vehicle propulsion or vehicle stall, either of which increases the risk of a crash.

Remedy

New flyer will reprogram the instrument panel free of charge. The safety recall began on january 9, 2012. New flyer will upload a corrected software version free of charge. Owners may contact new flyer at 1‑204‑934‑4876.

Recall number 12V002000 · Recall details

What is wrong

New flyer is recalling certain model year 2010 heavy duty transit buses, models d35lfr, d40lfr, d60lfr, de40lfr, de60lfr, xd35, xde35, and xde40, manufactured from september 30, 2010, through june 3, 2011, equipped with a cummins isb, isl, isc, or isx diesel engine. The v-band clamp assembly, part numbers q187684, q187685, and q187686, used to connect the inlet and outlet cone sections to the diesel oxidation catalyst (doc)/diesel particulate filter (dpf) include a t-bolt which can fracture and fail when subjected to stress or load. A fracture or failure of the t-bolt may cause the clamp to loosen and the inlet or outlet sections attached to the doc/dpf housing to disconnect.

Risk

If the inlet or outlet sections disconnect, hot exhaust gases can vent prior to exiting the tailpipe, creating the risk of combustion and a fire. If both clamps fail, there is a risk in some applications that the doc/dpf housing may detach completely, creating a road hazard.

Remedy

New flyer is working with cummins to identify and notify owners of the recall campaign. Repairs will be performed by authorized cummins dealers free of charge. The safety recall began on september 1, 2011. Owners may contact cummins at 1‑812‑377‑5000 or new flyer customer services at 1‑204‑934‑4876.

Recall number 11V431000 · Recall details