Recall 25V-566: 2019–2025 New Flyer XE35, 2013, 2017–2025 New Flyer XE40 and 3 more
New Flyer of America, Inc. recall for electrical system, reported to NHTSA on Aug 29, 2025, covering about 1,170 vehicles.
The 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.
The risk
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
| 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 |
| Recall started by | the manufacturer |
| NHTSA campaign number | 25V566000 |
Vehicles in this recall
| Vehicle | Model years | |
|---|---|---|
| New Flyer XE35 | 2019, 2020, 2021, 2022, 2023, 2024, 2025 | All years |
| New Flyer XE40 | 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025 | All years |
| New Flyer XE60 | 2019, 2020, 2021, 2022, 2023, 2024, 2025 | All years |
| New Flyer XHE40 | 2023, 2024, 2025 | All years |
| New Flyer XHE60 | 2024, 2025 | All years |
Not every vehicle of these model years is included. Enter your VIN at nhtsa.gov/recalls ↗ or ask a dealer.
Frequently asked questions
What is recall 25V-566?
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.
How is recall 25V-566 fixed?
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.
Is the recall repair free?
Yes. Safety recall repairs are free at authorized dealers. Check whether your vehicle is included with its VIN at nhtsa.gov/recalls.