2021 New Flyer Xd40 problems, complaints & recalls
Safety recalls (6)
Electronic Stability Control (Esc) 2025-12-19 · campaign 25V898000 · 6,673 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain XD35, XDE35, XE35, XN35, XD40, XDE40, XE40, XHE40, XN40, XT40, XD60, XDE60, XE60, XN60, XT60, and XHE60 transit buses. Please refer to New Flyer's recall report for specific model year information. The antilock braking (ABS) and electronic stability control (ESC) module may lose communication and fail without illuminating the warning lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Sta
Risk: An ABS or ESC warning light that fails to illuminate will not alert the driver to the loss of ABS or ESC, increasing the risk of a crash.
Fix: New Flyer will update the software, free of charge. Owner notification letters were mailed February 17, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.
Power Train:driveline:driveshaft 2023-10-26 · campaign 23V722000 · 2,351 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2019-2024 XD35, XD40, XN35, and XN40 transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.
Risk: A sudden loss of drive power can increase the risk of a crash.
Fix: New Flyer will work with the equipment manufacturer, Allison Transmission Inc., to inspect, and if necessary, tighten loose transmission yoke bolts, free of charge. Owner notification letters were mailed December 9, 2023. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-20.
Steering 2022-08-24 · campaign 22V637000 · 55 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XD40, XD60, XDE40, 2022 XN35, XE40, XN40, and 2021 XN60 transit buses. The steering gears may have been incorrectly assembled, which can cause the gear to fracture.
Risk: A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.
Fix: Dealers will inspect and replace the steering gear if required, free of charge. Owner notification letters were mailed on September 2, 2022. Owners may contact New Flyer's customer service at 1-204-224-6706. New Flyer's number for this recall is R22-026.
Fuel System, Diesel:delivery:hoses, Lines/Piping, And Fittings 2021-07-28 · campaign 21V576000 · 30 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD40 and XD35 vehicles equipped with Cummins L9 Diesel engines that have remote Stage 2 fuel filters and pressurized hoses. A fuel leak may occur from the fuel hose between the fuel pump and the remote fuel filter head.
Risk: A fuel leak in the presence of an ignition source increases the risk of a fire.
Fix: Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed on August 3, 2021. Owners may contact New Flyer's customer service at 1-204-224-6706.
Engine And Engine Cooling:exhaust System:manifold/Header/Muffler/Tail Pipe 2021-07-14 · campaign 21V532000 · 28 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD35 and XD40 vehicles equipped with 2021 Model Year Cummins L9 Diesel Engines. The engine calibration software's management of the injection of Diesel Exhaust Fluid can allow excessive ammonia to be emitted from tailpipe exhaust.
Risk: Exposure to high levels of ammonia can increase the risk of injury.
Fix: Cummins will recalibrate the engine, free of charge. Owner notification letters were mailed on July 23, 2021. Owners may contact New Flyer's customer service at 1-800-204-224-6706. New Flyer's number for this recall is R21-013.
Fuel System, Diesel:fuel Injection System:fuel Rail 2021-05-18 · campaign 21V365000 · 3,600 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2017-2021 XD40, XD35, 2016-2021 XD60, 2017 XDE35, 2016-2020 XDE40, XDE60 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.
Risk: A fuel leak in the presence of an ignition source increases the risk of a fire.
Fix: New Flyer will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R21-008.
Service bulletins (6)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Fuel/Propulsion System 2026-03-20 · ITS61086 · Service Bulletin/Repair Instructions
instructions to remove def sensor bypass calibration from engine ecm and new sensor installation ar - 12inch def tank
Seats 2025-07-07 · ITS61281 · Service Bulletin/Repair Instructions
instructions to adjust certain cantilever mounted seats and adjust them to proper height.
Steering 2025-01-09 · ITS61148 · Service Bulletin/Repair Instructions
instruction to service to check the four mounting bolts that attach the steering box mounting bracket to the frame of the bus to ensure they are torqued to the correct value.
Electrical System 2023-11-03 · ITS60838 · Service Bulletin/Repair Instructions
instruction to service 60838 to check/replace fuse box mounting hardware as required.
Equipment 2022-02-01 · ITS60381 · Service Bulletin/Repair Instructions
this instruction to service describes how to install a reminder decal for the sds panel retaining lanyard on specifically equipped buses.
Structure 2021-08-31 · ITS59303 · Service Bulletin/Repair Instructions
technical instruction describing hos to remove, rework, and replace the stop request sign support bracket, to promote clearance for electrical wiring.
What owners report
No detailed complaint narratives on file.
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.