CarRecallWatch- Component
- ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY; ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
- Problem
- 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.
What this recall means for you
Certain transit buses have a high-voltage traction battery where a weld on the busbar may be inadequate, and the battery management software may be incorrect. Together, these conditions can cause a battery module to overheat.
An overheating battery module increases the risk of a fire. Vehicle fires can cause serious injury and damage, so affected buses should be repaired promptly.
The repair is free. The manufacturer will inspect and replace the battery module as necessary and update the battery management system software at an authorized dealer. Owners were notified by letter on October 6, 2025, and can call New Flyer customer service at 1-800-241-2947. You can also check your vehicle identification number (VIN) for open recalls.
Check whether this recall is open on your vehicle
Official recall notice
Affected vehicles
| New Flyer XE35 | 2019202020212022202320242025 |
|---|---|
| New Flyer XE40 | 2013201720182019202020212022202320242025 |
| New Flyer XE60 | 2019202020212022202320242025 |
| New Flyer XHE40 | 202320242025 |
| New Flyer XHE60 | 20242025 |