2013–2025 New Flyer XE35, New Flyer XE40, New Flyer XE60 +more: Electrical System recall
NHTSA campaign 25V566000 · 1,170 units potentially affected · filed Aug 29, 2025
What's 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.
Why it matters
A battery module that overheats increases the risk of a fire.
The fix
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 details
- NHTSA campaign
- 25V566000
- Manufacturer no.
- —
- Manufacturer
- New Flyer OF America, Inc.
- Component
- ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY; ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
- Units affected
- 1,170
- Report received
- Aug 29, 2025
- Owner letters
- Oct 6, 2025
- Type
- Vehicle
Check whether your vehicle is included with the official NHTSA VIN lookup or your dealer. Repairs for safety recalls are free.
Vehicles covered
- New Flyer XE35 2019, 2020, 2021, 2022, 2023, 2024, 2025
- New Flyer XE40 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025
- New Flyer XE60 2019, 2020, 2021, 2022, 2023, 2024, 2025
- New Flyer XHE40 2023, 2024, 2025
- New Flyer XHE60 2024, 2025