The Recall Desk
SevereNHTSA·25V566000·Announced 2025-08-29

New Flyer Recalls Electric Buses Due to Battery Overheating Risk

New Flyer is recalling specific electric bus models because an inadequate weld and software error may cause battery modules to overheat, increasing the risk of fire.

What this means for you

Illness, injury, or structural failure has been reported. Stop using the product immediately and contact the manufacturer for a refund or repair.

Our severity reasoning: The recall involves a structural defect in the propulsion system (inadequate weld) that creates a significant risk of fire, meeting the criteria for a Severe rating.

Plain-English summary

New Flyer of America, Inc. is recalling certain 2013, 2017-2025 XE40, 2019-2025 XE60, XE35, 2023-2025 XHE40, and 2024-2025 XHE60 buses. The recall involves 1,170 vehicles affected by an inadequate weld on the high voltage battery busbar and incorrect software, which may cause the battery module to overheat.

A battery module that overheats increases the risk of a fire. No specific injuries or fatalities are reported in the source text.

New Flyer will inspect and replace the battery module as necessary and update the BMS software. All repairs will be performed free of charge. Owner notification letters were mailed on October 6, 2025. Owners may contact New Flyer's customer service at 1-800-241-2947.

The recalled product

Product
NEW FLYER XHE40, XE40, XE35, XE60
Brand
NEW FLYER
Manufacturer
New Flyer of America, Inc.
Category
Vehicle — Electric Bus
Hazard
Affected units
1,170

Is your product affected?

Check your packaging against the codes below. If any of them match, the product is part of this recall.

Model numbers (5)

  • XHE40
  • XE40
  • XE35
  • XE60
  • XHE60

Distribution

Distributed nationwide across the United States.

Related recalls

Same brand · NEW FLYER

Same manufacturer · New Flyer of America, Inc.

See all →

Same hazard · fire

See all →