New Flyer XD40 Recalls & Complaints by Model Year
NHTSA lists 23 safety recalls and 0 owner complaints across 17 model years of the New Flyer XD40 (2010–2026).
Pick your New Flyer XD40 model year
All New Flyer XD40 recalls (23)
Every NHTSA safety campaign that lists a New Flyer XD40, most recent first, with the model years each one covers.
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Electronic stability control (esc) and antilock (service brakes)
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…
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.
Model years: 2015, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025, 2026
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Hoses, lines/piping, and fittings (fuel system)
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.
Remedy: 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.
Model years: 2024
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Hoses, lines/piping, and fittings (fuel system)
New Flyer of America, Inc. (New Flyer) is recalling certain 2023 XD35, XD40, and XD60 vehicles equipped with certain Cummins L9 diesel engines. The remote fuel filter hoses may become separated from the fitting, which can result in a fuel leak and a lack of fuel supply to the engine.
Remedy: Cummins will replace the fuel filter hoses, free of charge. Owner notification letters are expected to be mailed July 21, 2024. Owners may contact New Flyer customer service at 1-800-241-2947.
Model years: 2023
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Vehicle speed control
New Flyer of America, Inc. (New Flyer) is recalling certain 2022-2023 XD35, XD40, XN35, XN40, and 2023 XD60, XE35, XE40, and XN60 transit buses. Due to a software error, unintended acceleration may occur during certain conditions.
Remedy: New Flyer will update the vehicle software, free of charge. Owner notification letters are expected to be mailed February 15, 2024. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number…
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Driveshaft (power train)
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.
Remedy: 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,…
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Labels (equipment)
New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2023 XD35, 2022-2023 XD40, XD60, XN35, XN60, 2022 XDE35, and 2021-2022 XE40 transit buses. The Gross Axle Weight Rating (GAWR) and Gross Vehicle Weight Rating (GVWR) listed on the certification labels are incorrect, which can allow the vehicle to be overloaded. As such,…
Remedy: New Flyer will provide and/or install new labels, free of charge. Owner notification letters were mailed November 9, 2023. Owners may contact New Flyer customer service at 1-800-241-2947.
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Steering
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.
Remedy: 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…
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Hoses, lines/piping, and fittings (fuel system)
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.
Remedy: 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.
Model years: 2021
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Manifold/header/muffler/tail pipe (engine and engine cooling)
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.
Remedy: 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…
Model years: 2021
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Fuel rail (fuel system)
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.
Remedy: 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…
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Sun/moon roof assembly (visibility)
New Flyer Industries Ltd. (New Flyer) is recalling certain 2018 XDE60 and XD40, 2018-2019 XN40, and 2019 XE60 heavy duty urban transit buses. The affected vehicles are equipped with an AS-3 tempered glass panel in the rooftop emergency escape hatch that may shatter in extreme cold temperatures.
Remedy: New Flyer has notified owners, and dealers will replace the tempered glass panel, free of charge. The recall began on March 6, 2019. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number…
Model years: 2018
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Equipment
New Flyer of America, Inc. (New Flyer) is recalling certain 2015-2017 New Flyer XD40 and XN60, 2015 XD60 and XDE40 and 2013-2017 XN40 vehicles, equipped with certain Kidde Technologies, Inc. (KTI) KDS-25 fire extinguishers as part of the optional fire suppression system. The actuator of the extinguisher may not function properly,…
Remedy: New Flyer has notified owners, and KTI will inspect the fire suppression systems and replace the electrical piston actuators, as necessary, free of charge. The recall began on November 29, 2018. Owners may contact New…
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Antilock (service brakes)
New Flyer of America Inc. (New Flyer) is recalling certain 2017 XD40, XDE40, XN40, XT60, and 2016-2017 XDE60 transit buses. The air brake hose connections for the front axle ABS modulator valves may not be properly tightened, possibly resulting in the air brake hose disconnecting. As such, these vehicles fail to comply with the…
Remedy: New Flyer will notify owners, and will reconnect the air hose using the proper tightness, free of charge. The recall began on January 11, 2018. Owners may contact New Flyer customer service at 1-204-224-6706. New…
Model years: 2017
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Buckle assembly (seat belts) and seat belts
New Flyer Industries Ltd. (New Flyer) is recalling certain 2015-2016 MD30, 2016 MD35, 2017 XD35, XD60, XDE35, XDE40, XDE60, XN35 and 2016-2017 XD40 and XN40 transit buses, equipped with certain Recaro Commercial Bus Driver Seats (models Ergo R, Ergo D, AM71, AM72 and AM80). The seat belt buckle may be stuck in the locked position,…
Remedy: New Flyer has notified owners and work with the supplier to replace the buckle housings, free of charge. The recall began September 15, 2017. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyers'…
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Software (electrical system)
New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 C40LFR, XN35, 2014-2016 XD35, XD60, XDE40, 2015-2016 XD40, XDE60, 2014 XDE35, 2013-2015 XE40, 2013-2016 XN40, XN60, and 2014-2015 XT40, and XT60 transit buses. These buses have an Electric Transit Operator (ETO) controller that controls the bus door motor…
Remedy: New Flyer will notify owners, and dealers will install a firmware upgrade, and replace the roller bracket plates, free of charge. The recall began on May 4, 2016. Owners may contact New Flyer customer service at…
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Seats
New Flyer Industries, Ltd. (New Flyer) is recalling certain model year 2015 New Flyer MD30, 2012 C35LFR, 2010-2011 D35LFR, NABI 35LFW, 2011 D40LFR, 2010-2012 D60LFR and NABI 31LFW, 2010 C40LF, DE35LF, D40LF, DE40LFA, DE60LFA, GE35LFR and GE40LF, 2009 DE60LF and GE40LFR, 2010-2013 C40LFR, DE60LFR, NABI 416 and NABI 60BRT, 2010-2015 XD35,…
Remedy: New Flyer will notify owners instructing them to inspect their seats for missing welds. Recaro will supply replacement anchorage brackets and cover the labor to replace them if any welds are missing, free of charge.…
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Tie rod assembly (steering)
New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2014-2015 New Flyer XDE40 and XD40, 2014 XD60, XN35 and XN60, 2015 XDE35, and 2013-2015 XN40 transit buses. The affected vehicles may be equipped with an improperly torqued front axle center link retaining clamp on the tie rod. As a result, the tie rod may disconnect,…
Remedy: New Flyer will notify owners, and dealers will inspect the vehicles to verify that the center link retaining clamp is properly torqued. Any components displaying play or movement will be replaced. These repairs will be…
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Service brakes, air
New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 XD35, XDE35, XE40, and 2013-2014 XD40, XD60, XDE40, XDE60, XN35, XN40, and XN60 transit buses. During installation, the Brake Pedal Mounting Plate may have been clamped between the Brake Pedal Assembly and the Brake Valve Actuator (BVA) resulting in a…
Remedy: New Flyer will notify owners and will replace the brake pedal mounting plate and the Brake Valve Actuator (BVA), free of charge. The recall began on September 15, 2014. Owners may contact New Flyer customer service at…
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Fuel system, diesel
New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2014 MD30, XD40, XD60, XDE40, and XDE60 transit buses. The Cummins ISB or ISL engines in these vehicles may have been equipped with Fleetguard UFF-XT fuel filters, part number FF63009, whose filter shell may separate from the fuel filter nut plate causing the engine…
Remedy: New Flyer will notify owners, and Cummins dealers will replace the fuel filter with a new one, free of charge. The recall began in August 2014. Owners may contact New Flyer customer service at 1-204-934-4876 or Cummins…
Model years: 2014
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Service brakes, air
New Flyer Industries Ltd. (New Flyer) is recalling certain model year 2013 XD40 buses manufactured May 24, 2013, through September 5, 2013; model year 2013 XN40 buses manufactured April 18, 2013, through September 11, 2013; model year 2013 XD60 buses manufactured May 31, 2013, through September 5, 2013; and model year 2013 XDE40 buses…
Remedy: New Flyer has notified owners, and dealers will inspect, and correct the air line routing, as needed, free of charge. Owners may contact New Flyer at 1-204-982-8400. New Flyer's recall number is R13-023.
Model years: 2013
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Switch (electrical system)
New Flyer Industries is recalling certain model year 2012 XD35 and XD40, model year 2013 XD60, XDE40 and XDE60 and model year 2012-2013 XN40 and XN60 transit buses. In the affected buses, the push-to-start button switch may have a weak return spring, allowing the engine to start unexpectedly.
Remedy: New Flyer will notify owners, and dealers will inspect and replace the switches free of charge. The recall began June 19, 2013. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's recall number…
Model years: 2012
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Parking brake
New Flyer is recalling certain model year 2010-2012 transit buses, models C40LF, C40LFR, D35LFR, D40LFR, D60LFR, XD35, XD40, XDE35, XDE40, and XN40. Air pressure may leak from the parking brake chambers causing the parking brakes to drag while the vehicle is driven.
Remedy: New Flyer will notify the owners and the affected brake chambers will be replaced, free of charge. The recall began on November 13, 2012. Owners may contact New Flyer at 1-204-224-6706 for more information.
Model years: 2011
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Instrument cluster/panel (electrical system)
New flyer is recalling certain model years 2009-2012 xde40, model years 2010-2011 models xd35 and xde35, model year 2010 xd40, and model year 2011 xn40 transit buses, manufactured from january 2010, through december 2011, and equipped with a parker-hannifin (vansco) instrument panel. The programming of the instrument panel is such that…
Remedy: New flyer will reprogram the instrument panel free of charge. The safety recall began on january 9, 2012. New flyer will upload a corrected software version free of charge. Owners may contact new flyer at 1-204-934-4876.
Model years: 2010
Other New Flyer models
- Xcelsior4 complaints
- D40LF2 complaints
- XD602 complaints
- C40FLR1 complaints
- C40LF1 complaints
- D60LFR1 complaints
- GE40LF1 complaints
- XT401 complaints
Source: NHTSA recall and complaint databases and EPA fuel economy data, October 2026. Complaint counts are owner reports to NHTSA, not verified defects. Recall counts are safety campaigns that list this model year; whether a particular car was already repaired depends on its VIN. How this data is compiled.