The worst 2023 New Flyer XHE40 problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
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Recalls 4
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: management system/energy control module (bms/becm): software
- 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
Technical service bulletins for the 2023 New Flyer XHE40 8
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- This ITS provides instructions on how to replace the air intake assembly on certain fuel cells
- Instructions to replace the original pressure relief valve with a new part with a lower set pressure point.
- This Bulletin is being issued due to New Flyer & MCI have received reports that customers are re-torquing...
- Instruction to Service to update vehicles with ELFA 3 to provide improved BMS response to overcharging and...
- Instruction to Service for updating ESS drains, remove internal mechanism, re-install and add duckbill
- Instruction to Service to rework end fairings and add support brackets for XHE40 buses.
- Instruction to Service for updating the battery program on certain ELFA3 buses for Improved BMS response...
- Instruction to Service for inspection and correction of side console illumination lamps.
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Questions about the 2023 New Flyer XHE40
Is the 2023 New Flyer XHE40 reliable?
Owners have filed 0 complaints about the 2023 New Flyer XHE40.
What is the most common problem with the 2023 New Flyer XHE40?
There are not enough complaints to tell.
How many recalls does the 2023 New Flyer XHE40 have?
4 recalls, covering electrical system and service brakes, air.
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