Recall 25V566000: 2019–2025 New Flyer XE35, 2013–2025 New Flyer XE40, 2019–2025 New Flyer XE60 +2 more

Updated from NHTSA data · How we count

Report date
Aug 29, 2025
Vehicles affected
1,170
Models
5
Initiated by
Manufacturer

The problem

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.

The risk

A battery module that overheats increases the risk of a fire.

The 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.

Affected vehicles

Details

NHTSA campaign
25V566000
Manufacturer
New Flyer of America, Inc.
Owner letters
Oct 6, 2025
Components
Electrical system:propulsion system:traction battery (Electrical System); Electrical system:propulsion system:traction battery:management system/energy control module (bms/becm):software (Electrical System)

Recall repairs are free at authorized dealers. To see if your vehicle is included, enter your VIN at NHTSA.gov or call the manufacturer.

Source: U.S. National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation public data. Complaints are submitted by owners and are not verified by NHTSA or by us; a complaint does not prove a defect exists. Methodology