The worst 2016 New Flyer XN40 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 6
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
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
Equipment
- What is wrong
- New Flyer of America, Inc. (New Flyer) is recalling certain 2015-2017 New Flyer XD40 and XN60, 2015 XD60 and XDE40 and 2013-2017 XN40 vehicles, equipped with certain Kidde Technologies, Inc. (KTI) KDS-25 fire extinguishers as part of the optional fire suppression system. The actuator of the extinguisher may not function properly, preventing the fire extinguisher from discharging the fire suppression agent in the event of a fire.
- Risk
- If the fire suppression system does not work as intended, it can increase the risk of injury in the event of a fire.
- Remedy
- New Flyer has notified owners, and KTI will inspect the fire suppression systems and replace the electrical piston actuators, as necessary, free of charge. The recall began on November 29, 2018. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R18-020.
Recall number 18V827000 · Recall details
Seat belts: front: buckle assembly
- 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
Fuel system, other
- What is wrong
- New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2016 New Flyer XN60 and XN40 Xcelsior transit buses manufactured June 22, 2016, to September 14, 2016, powered by compressed natural gas (CNG). The pressure relief device (PRD) of the CNG system may fracture and separate, allowing a high pressure release of CNG.
- Risk
- An unexpected release of CNG gas in the presence of an ignition source increases the risk of a fire.
- Remedy
- New Flyer has notified owners, and dealers will install new a vent tubing system and replace the PRD, free of charge. The recall began September 28, 2016. Owners may contact New Flyer customer service at 1‑204‑224‑6706. New Flyer's number for this recall is R16-026. Note: Owners are advised to remove the vehicles from operation until the recall remedy can be applied.
Recall number 16V678000 · Recall details
Electrical system: software
- 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
Technical service bulletins for the 2016 New Flyer XN40 25
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Instructions for replacing a CNG decal to comply with New York State regulations
- Instructions to Service to incorporate a PLC Update to prevent interlock activation when CAN speed...
- Technical Instruction describing how to remove and replace the front suspension air springs
- Service Manual Bulletin
- Technical Service Information Bulletin describing changes to the Cummins ISLG, L9N, ISB6.7G and B6.7N...
- Technical Service Instruction Describing How to Rewire TRW Steering Column to Provide a Memory Power Circuit
- This Technical Service Information Bulletin Decsribes How to Inspect and Reroute as Required the Cummins...
- This Maintenance Instruction Describes How to Install CNG Diamond Decals on the Sides of the Vehicle
- This Maintenance Instruction Decribes How to Replace the Surge Tank Low Coolant Level Sensor.
- This Maintenance Instruction Decribes How to Update Battery Equalizer Programming.
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Questions about the 2016 New Flyer XN40
Is the 2016 New Flyer XN40 reliable?
Owners have filed 0 complaints about the 2016 New Flyer XN40.
What is the most common problem with the 2016 New Flyer XN40?
There are not enough complaints to tell.
How many recalls does the 2016 New Flyer XN40 have?
6 recalls, covering service brakes, air, steering and equipment.
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