The worst 2020 New Flyer XD40 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
Recalls 3
Electronic stability control (ESC)
- 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
Power train: driveline: driveshaft
- 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
Fuel system, diesel: fuel injection system: fuel rail
- 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
Technical service bulletins for the 2020 New Flyer XD40 13
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Instructions to adjust certain cantilever mounted seats and adjust them to proper height.
- Instructions to Service to remove bypassed engine calibration from ECM and replace DEF sensor as required.
- Instruction to Service 60838 to check/replace fuse box mounting hardware as required.
- Instruction to Service to replace bracket to provide additional clearance on HVAC cable.
- ITS was issued to perform an inspection and replacement of fuse box fasteners if necessary
- This Instruction to Service describes how to install a reminder decal for the SDS panel retaining lanyard...
- Technical Instruction describing hos to remove, rework, and replace the stop request sign support bracket,...
- This instruction to service describes how to inspect specifically equipped vehicles for SDS Window...
- This technical service instruction describes how to remove and replace SDS Window strike pins and remove...
- Technical Instruction describing how to inspect and install new headlamp harness if required.
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Questions about the 2020 New Flyer XD40
Is the 2020 New Flyer XD40 reliable?
Owners have filed 0 complaints about the 2020 New Flyer XD40.
What is the most common problem with the 2020 New Flyer XD40?
There are not enough complaints to tell.
How many recalls does the 2020 New Flyer XD40 have?
3 recalls, covering electronic stability control (esc), power train and fuel system, diesel.
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