2023 New Flyer Xhe40 problems, complaints & recalls
Safety recalls (4)
Electrical System:propulsion System:inverter 2026-03-13 · campaign 26V151000 · 1,196 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2025 XE35, 2021-2026 XE40, 2023-2025 XE60, 2023-2026 XHE40, and 2024-2026 XHE60 transit buses equipped with Accelera ELFA 3 control systems V1 and V2. An inverter software error may cause unintended acceleration or deceleration in certain conditions.
Risk: Unintended acceleration or deceleration can increase the risk of a crash.
Fix: New Flyer will update the inverter software, free of charge. Owner notification letters were mailed April 30, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.
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.
Electrical System:propulsion System:traction Battery 2025-08-29 · campaign 25V566000 · 1,170 vehicles
Defect: 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.
Risk: A battery module that overheats increases the risk of a fire.
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.
Electrical System:propulsion System:traction Battery:thermal Management:fluid/Coolant 2024-01-31 · campaign 24V056000 · 337 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40, 2021-2024 XE60, and 2023-2024 XHE40 vehicles. One or more drain valves may not activate as intended, which could allow battery packs to accumulate liquid in the battery pack enclosure.
Risk: The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.
Fix: New Flyer will remove the rubber washer from the affected drain valves, free of charge. Owner notification letters were mailed March 14, 2024. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R24-02. This recall is in addition to NHTSA recall number 23V-083. Certain vehicles are affected by both recalls and will need to have both remedies performed.
Service bulletins (8)
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 2026-05-07 · ITS61693 · Service Bulletin/Repair Instructions
this its provides instructions on how to replace the air intake assembly on certain fuel cells. this is required due to the air filter for the original intake has been obsoleted by the supplier.
Fuel/Propulsion System 2025-10-02 · ITS61424 · Service Bulletin/Repair Instructions
instructions to replace the original pressure relief valve with a new part with a lower set pressure point.
Fuel/Propulsion System 2025-08-21 · TSIB 25-07 · Service Bulletin/Repair Instructions
this bulletin is being issued due to new flyer & mci have received reports that customers are re-torquing high-voltage (hv) connections during preventative maintenance inspections as outlined in the preventive maintenance section of the service or maintenance manual. this bulletin reminds operators
Fuel/Propulsion System 2025-02-14 · ITS61268 · Service Bulletin/Repair Instructions
instruction to service to update vehicles with elfa 3 to provide improved bms response to overcharging and other functional safety mechanisms, more robust detection of failure modes through dtcs, battery data recorder (bdr) capabilities, and streamlined flashing processes.
Fuel/Propulsion System 2025-02-07 · ITS61252 · Service Bulletin/Repair Instructions
instruction to service for updating ess drains, remove internal mechanism, re-install and add duckbill. remove the ess breather, extract the internal mechanism, remove the three desiccant bags and reinstall the breather. 2 string buses.
Structure:body 2024-08-29 · ITS61127 · Service Bulletin/Repair Instructions
instruction to service to rework end fairings and add support brackets for xhe40 buses.
Showing the 6 most recent of 8 bulletins. Search all of them free at nhtsa.gov.
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.