RoadVitals

2021 New Flyer XD40

Recalls, owner-reported complaints, investigations and safety data

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
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Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
6
Latest Dec 19, 2025
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
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Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
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Overview

Our database contains no NHTSA owner-reported complaints for the 2021 New Flyer XD40. 6 safety recalls have been issued covering this model year; and 6 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Safety recalls

6 campaigns cover this model year

View all 6

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
25V898000

ELECTRONIC STABILITY CONTROL (ESC); SERVICE BRAKES, AIR:ANTILOCK

Dec 19, 2025
6,673 units potentially affected
The 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."
The 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.
The 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.
New Flyer of America, Inc.View on NHTSA.gov
23V722000

POWER TRAIN:DRIVELINE:DRIVESHAFT

Oct 26, 2023
2,351 units potentially affected
The defect: 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.
The risk: A sudden loss of drive power can increase the risk of a crash.
The 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, 2023. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-20.
New Flyer of America, Inc.Manufacturer number R23-20View on NHTSA.gov
22V637000

STEERING

Aug 24, 2022
55 units potentially affected
The defect: 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.
The risk: A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.
The 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 Flyer's number for this recall is R22-026.
New Flyer of America, Inc.Manufacturer number R22-026View on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

No owner complaints recorded for this model year

Either none have been filed with NHTSA, or this vehicle is too new for reports to have accumulated.

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

ITS61086

ENGINE; FUEL/PROPULSION SYSTEM

Instructions to remove DEF sensor bypass calibration from engine ECM and new sensor installation AR - 12inch DEF tank

ITS61281

SEATS

Instructions to adjust certain cantilever mounted seats and adjust them to proper height.

ITS61148

STEERING

Instruction to Service to check the four mounting bolts that attach the steering box mounting bracket to the frame of the bus to ensure they are torqued to the correct value.

ITS60838

ELECTRICAL SYSTEM

Instruction to Service 60838 to check/replace fuse box mounting hardware as required.

ITS60381

EQUIPMENT

This Instruction to Service describes how to install a reminder decal for the SDS panel retaining lanyard on specifically equipped buses.

ITS59303

ELECTRICAL SYSTEM:WIRING; EQUIPMENT; STRUCTURE

Technical Instruction describing hos to remove, rework, and replace the stop request sign support bracket, to promote clearance for electrical wiring.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

New Flyer XD40 by model year
YearComplaintsRecallsInvestigationsIssue Index
2026010—
2025010—
2024030—
2023050—
2022050—
2021Viewing060—
2020030—
2019030—
2018030—
2017050—
2016030—
2015050—
2014040—
2013030—
2012020—
2011021—
2010010—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.