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
Our assessment, not the agency’s: severity 4/5 (Severe).
The hazard poses a serious risk of illness, injury, or structural failure. 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 XE60, XHE40, XE40, XE35
- 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)
- XE60
- XHE40
- XE40
- XE35
- XHE60
Distribution
Distributed nationwide across the United States.
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