2021 NEW FLYER XD40 recalls
The 2021 NEW FLYER XD40 is covered by 6 recall campaigns. Repairs are free at a dealer; check your VIN to see which are still open.
| Campaign | Received | Component |
|---|---|---|
| 25V898000 | 2025-12-19 | Electronic Stability Control (Esc) |
| 23V722000 | 2023-10-26 | Power Train › Driveline › Driveshaft |
| 22V637000 | 2022-08-24 | Steering |
| 21V576000 | 2021-07-28 | Fuel System, Diesel › Delivery › Hoses, Lines/Piping, And Fittings |
| 21V532000 | 2021-07-14 | Engine And Engine Cooling › Exhaust System › Manifold/Header/Muffler/Tail Pipe |
| 21V365000 | 2021-05-18 | Fuel System, Diesel › Fuel Injection System › Fuel Rail |
Each recall: problem, risk and fix
Electronic Stability Control (Esc) (25V898000, 2025-12-19)
Problem: 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."
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.
Free 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 (23V722000, 2023-10-26)
Problem: 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.
Free 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 (22V637000, 2022-08-24)
Problem: 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.
Free 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 (21V576000, 2021-07-28)
Problem: 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.
Free 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 (21V532000, 2021-07-14)
Problem: 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.
Free 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 (21V365000, 2021-05-18)
Problem: 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.
Free 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.
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