2023 New Flyer Xe60 problems

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.

Consequence

Unintended acceleration or deceleration can increase the risk of a crash.

Remedy

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.

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 Standard numbers 121, "Air Brake Systems" and 136, "Electronic Stability Control Systems on Heavy Vehicles."

Consequence

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.

Remedy

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.

Defect

New Flyer of America, Inc. (New Flyer) is recalling certain 2019 XE35, 2021-2025 XE35, XE40, and XE60 transit buses. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity.

Consequence

A short circuit in a high voltage battery increases the risk of a fire.

Remedy

Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. New Flyer will replace the batteries, free of charge. This is a Phased campaign. Phase 1 will include 35 buses. New Flyer notified owners on 3/24/2026. Phase 2 will include 100 buses. New Flyer will notify owners on or about 6/15/2026. Phase 3 will include 120 buses. New Flyer will notify owners on or about 9/16/2026. Phase 4 will include 120 buses. New Flyer will notify owners on or about 12/14/2026. Phase 5 will include 120 buses. New Flyer will notify owners on or about 3/15/2027. Phase 6 will include 80 buses. New Flyer will notify owners on or about 6/14/2027. Phase 7 will include 80 buses. New Flyer will notify owners on or about 9/27/2027. Interim owner notification letters explaining the safety risk were mailed November 12, 2025. A second letter will be sent once the remedy is available. Owners may contact New Flyer's customer service at 1-800-241-2947.

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.

Consequence

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

Remedy

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.

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.

Consequence

The accumulation of liquid inside the battery pack enclosure may lead to an electrical short, increasing the risk of a fire.

Remedy

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.

Defect

New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XE35, XE40 and 2023 XE60 battery electric transit buses. Due to a software error, unintended acceleration may occur during certain conditions.

Consequence

Unintended acceleration can increase the risk of a crash.

Remedy

New Flyer will update the vehicle software, free of charge. Owner notification letters were mailed February 13, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-023.