The worst 2022 New Flyer XE40 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 13
Electrical system: instrument cluster/panel
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2013-2027 buses. Please see the complete list of models above. The instrument panel indicator light may not illuminate when the hazard warning lights are on and the master run switch is in the 'Off' position. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, "Lamps, Reflective Devices, and Associated Equipment."
- Risk
- Without the illuminated reminder, the driver may fail to turn off the exterior lights when no longer needed. Hazard warning lights that remain activated unintentionally can confuse other drivers, increasing the risk of a crash.
- Remedy
- New Flyer will update the software, free of charge. Owner notification letters are expected to be mailed November 20, 2026. Owners may contact New Flyer's customer service at 1‑800‑241‑2947.
Recall number 26V644000 · Recall details
Electrical system: instrument panel: speedometer/odometer
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2022 XE40 transit buses. The speedometer may not illuminate when the headlights are turned on. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 101, "Controls and Displays."
- Risk
- An unlit speedometer cannot show the vehicle's speed, increasing the risk of a crash.
- Remedy
- New Flyer will update the software, free of charge. Owner notification letters are expected to be mailed June 15, 2026. Owners may contact New Flyer's customer service at 1‑800‑241‑2947.
Recall number 26V279000 · Recall details
Electrical system: propulsion system: inverter
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2025 XE35, 2021-2026 XE40, 2023-2025 XE60, 2023-2026 XHE40, and 2024-2026 XHE60 transit buses equipped with Accelera ELFA 3 control systems V1 and V2. An inverter software error may cause unintended acceleration or deceleration in certain conditions.
- Risk
- Unintended acceleration or deceleration can increase the risk of a crash.
- Remedy
- New Flyer will update the inverter software, free of charge. Owner notification letters were mailed April 30, 2026. Owners may contact New Flyer's customer service at 1‑800‑241‑2947.
Recall number 26V151000 · Recall details
Service brakes, air: antilock
- 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
Electrical system: propulsion system: traction battery
- What is wrong
- 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.
- Risk
- A short circuit in a high voltage battery increases the risk of a fire.
- Remedy
- 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 notified owners on 6/25/2026. Phase 3 will include 120 buses. New Flyer will notified owners on 9/9/2026. 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.
Recall number 25V631000 · Recall details
Electrical system: propulsion system: traction battery
- What is wrong
- 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.
- Risk
- A battery module that overheats increases the risk of a fire.
- 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.
Recall number 25V566000 · Recall details
Electrical system: propulsion system: traction battery: thermal management: fluid/coolant
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40, 2021-2024 XE60, and 2023-2024 XHE40 vehicles. One or more drain valves may not activate as intended, which could allow battery packs to accumulate liquid in the battery pack enclosure.
- Risk
- The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.
- Remedy
- New Flyer will remove the rubber washer from the affected drain valves, free of charge. Owner notification letters were mailed March 14, 2024. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R24-02. This recall is in addition to the federal safety agency recall number 23V‑083. Certain vehicles are affected by both recalls and will need to have both remedies performed.
Recall number 24V056000 · Recall details
Vehicle speed control
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40 and 2023 XE60 battery electric 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 were mailed February 13, 2024. Owners may contact New Flyer customer service at 1‑800‑241‑2947. New Flyer's number for this recall is R23-023.
Recall number 23V897000 · Recall details
Vehicle speed control
- 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
Equipment: other: labels
- 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
Electrical system: propulsion system: traction battery: thermal management: fluid/coolant
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XE35, 2021-2023 XE40, and 2021-2022 XE60 electric buses. One or more battery packs may accumulate liquid in the battery pack enclosure.
- Risk
- The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.
- Remedy
- If liquid accumulation is found, the bus should not be operated, and should be parked outside and away from structures until repaired. Dealers will add four holes and automatic activating drain valves to each battery pack enclosure, free of charge. Owner notification letters were mailed May 3, 2023. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R23-002.
Recall number 23V083000 · Recall details
Steering: column
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2013-2022 XDE35, XDE40, XDE60, XE40, XN40, 2017-2022 XE60, 2014-2022 XT40 and XT60 transit buses equipped with a double tilt steering column. The steering column connection to the upper steering shaft may become loose.
- Risk
- A loose steering shaft can cause a loss of steering, increasing the risk of a crash.
- Remedy
- Dealers will replace the steering column and shaft components, free of charge. Owner notification letters were mailed on February 1, 2023. Owners may contact New Flyer's customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R22-035.
Recall number 22V943000 · Recall details
Steering
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XD40, XD60, XDE40, 2022 XN35, XE40, XN40, and 2021 XN60 transit buses. The steering gears may have been incorrectly assembled, which can cause the gear to fracture.
- Risk
- A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.
- Remedy
- Dealers will inspect and replace the steering gear if required, free of charge. Owner notification letters were mailed on September 2, 2022. Owners may contact New Flyer's customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R22-026.
Recall number 22V637000 · Recall details
Technical service bulletins for the 2022 New Flyer XE40 29
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Instructions to upload latest program per customer requests to revise ESS SNSR FAULT telltale to amber...
- Instruction to program for the addition of ESS cell minimum and maximum voltages and ESS charge current...
- Instructions for uploading the latest software version
- Instructions to rework overhead cables by adding a moisture barrier to mitigate water intrusion.
- Instructions to update V2 traction inverters with new bootloader.
- A consumer notification indicating one of New Flyer's battery suppliers is exiting the market.
- This Bulletin is being issued due to New Flyer & MCI have received reports that customers are re-torquing...
- Instructions to Service for an update to the HV DC charge box contactors to replace the existing GIGAVAC...
- This Technical Service Information Bulletin has been issued to remind customers that fill pressure must...
- Instruction to Service to update vehicles with ELFA 3 to provide improved BMS response to overcharging and...
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Questions about the 2022 New Flyer XE40
Is the 2022 New Flyer XE40 reliable?
Owners have filed 0 complaints about the 2022 New Flyer XE40.
What is the most common problem with the 2022 New Flyer XE40?
There are not enough complaints to tell.
How many recalls does the 2022 New Flyer XE40 have?
13 recalls, covering electrical system, service brakes, air and vehicle speed control.
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