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Vehicle recall 25V566000 · August 29, 2025

New Flyer XE40, XE35 and 3 more models

An inadequate weld on the high voltage battery busbar and incorrect software may cause the battery module to overheat.

Source: NHTSA data as of September 22, 2026. Last refreshed Sep 23, 2026, 2:43 AM UTC.

Summary
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.

Recall details

NHTSA campaign
25V566000
Reported to NHTSA
August 29, 2025
Filed by
New Flyer of America, Inc.
Owner notification
October 6, 2025
Vehicles potentially affected
1,170
Initiated by
the manufacturer
Components
Electrical system › Propulsion system › Traction battery; Electrical system › Propulsion system › Traction battery › Management system/energy control module (bms/becm) › Software
Recall 25V566000 on nhtsa.gov, with the manufacturer’s documents

Vehicles covered

As listed by NHTSA. A recall usually covers only some vehicles of each model and year, often a production date range.

Has your New Flyer been repaired?

Recalls here come from NHTSA’s records for the model and year. Not every vehicle of a model is included in every recall, and this site can’t see whether a repair has been done. Only a VIN lookup can tell you that.

NHTSA’s VIN search doesn’t show recalls that were already repaired, recalls more than 15 years old, or some small manufacturers’ recalls. A New Flyer dealer can also check your VIN. Recall repairs are free.