2024 New Flyer Xd40 problems, complaints & recalls
Safety recalls (3)
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.
Fuel System, Diesel:delivery:hoses, Lines/Piping, And Fittings 2025-02-03 · campaign 25V053000 · 210 vehicles
Defect: New Flyer of America, Inc. (New Flyer) is recalling certain 2023-2024 XDE60, 2024 XD35, XD40, and XD60 transit buses equipped with Cummins L9 diesel engines. The remote fuel filter hoses may separate from the fitting, causing a fuel leak and an engine stall.
Risk: A fuel leak in the presence of an ignition source increases the risk of a fire. An engine stall increases the risk of a crash.
Fix: Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed March 11, 2025. Owners may contact Cummins customer service at 1-800-286-6467 or New Flyer 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.
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.
Seats 2026-09-22 · ITS61870 · Service Bulletin/Repair Instructions
instructions provided to remove the existing brass/plastic swivel fitting and replacing with a more reliable solid brass fixed position fitting.
Electrical System 2026-05-23 · ITS61748 · Service Bulletin/Repair Instructions
instructions for verifying/correcting torque on front destination sign mounting hardware installed on certain buses.
Engine 2025-03-06 · ITS61283 · Service Bulletin/Repair Instructions
instruction to service to replace existing turbo outlet exhaust elbow with redesigned elbow and gasket
Engine 2025-03-04 · ITS61038 · Service Bulletin/Repair Instructions
instructions to replace the a/c belt sheave (pulley) with an improved version to mitigate the ac belt splitting.
Power Train 2024-07-24 · ITS61103 · Service Bulletin/Repair Instructions
service instruction to validate torque on engine cradle mounts.
Electrical System:propulsion System:traction Battery:thermal Management:hoses, Fittings, And Reservoir 2024-03-22 · ITS60981 · Service Bulletin/Repair Instructions
instructions to service to revert plc wake-up configuration to the original circuit (modified configuration is not required with a 400a bistable relay).
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.