Recall 25V-631: 2019, 2021–2025 New Flyer XE35, 2021–2025 New Flyer XE40 and 1 more
New Flyer of America, Inc. recall for electrical system, reported to NHTSA on Sep 19, 2025, covering about 655 vehicles.
The problem
New Flyer of America, Inc. (New Flyer) is recalling certain 2019 XE35, 2021-2025 XE35, XE40, and XE60 transit buses. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity.
The risk
A short circuit in a high voltage battery increases the risk of a fire.
The fix
Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. New Flyer will replace the batteries, free of charge. This is a Phased campaign. Phase 1 will include 35 buses. New Flyer notified owners on 3/24/2026. Phase 2 will include 100 buses. New Flyer notified owners on 6/25/2026. Phase 3 will include 120 buses. New Flyer will notified owners on 9/9/2026. Phase 4 will include 120 buses. New Flyer will notify owners on or about 12/14/2026. Phase 5 will include 120 buses. New Flyer will notify owners on or about 3/15/2027. Phase 6 will include 80 buses. New Flyer will notify owners on or about 6/14/2027. Phase 7 will include 80 buses. New Flyer will notify owners on or about 9/27/2027. Interim owner notification letters explaining the safety risk were mailed November 12, 2025. A second letter will be sent once the remedy is available. 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 |
| Recall started by | NHTSA (Office of Defects Investigation) |
| NHTSA campaign number | 25V631000 |
Vehicles in this recall
| Vehicle | Model years | |
|---|---|---|
| New Flyer XE35 | 2019, 2021, 2022, 2023, 2024, 2025 | All years |
| New Flyer XE40 | 2021, 2022, 2023, 2024, 2025 | All years |
| New Flyer XE60 | 2021, 2022, 2023, 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-631?
New Flyer of America, Inc. (New Flyer) is recalling certain 2019 XE35, 2021-2025 XE35, XE40, and XE60 transit buses. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity.
How is recall 25V-631 fixed?
Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. New Flyer will replace the batteries, free of charge. This is a Phased campaign. Phase 1 will include 35 buses. New Flyer notified owners on 3/24/2026. Phase 2 will include 100 buses. New Flyer notified owners on 6/25/2026. Phase 3 will include 120 buses. New Flyer will notified owners on 9/9/2026. Phase 4 will include 120 buses. New Flyer will notify owners on or about 12/14/2026. Phase 5 will include 120 buses. New Flyer will notify owners on or about 3/15/2027. Phase 6 will include 80 buses. New Flyer will notify owners on or about 6/14/2027. Phase 7 will include 80 buses. New Flyer will notify owners on or about 9/27/2027. Interim owner notification letters explaining the safety risk were mailed November 12, 2025. A second letter will be sent once the remedy is available. 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.