RoadVitals

2025 New Flyer XHE40

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.
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Latest Mar 13, 2026
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 2025 New Flyer XHE40. 3 safety recalls have been issued covering this model year; and 10 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

3 campaigns cover this model year

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
26V151000

ELECTRICAL SYSTEM:PROPULSION SYSTEM:INVERTER

Mar 13, 2026
1,196 units potentially affected
The 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.
The risk: Unintended acceleration or deceleration can increase the risk of a crash.
The 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.
New Flyer of America, Inc.View 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
25V566000

ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY; ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE

Aug 29, 2025
1,170 units potentially affected
The 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.
The risk: A battery module that overheats increases the risk of a fire.
The 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.
New Flyer of America, Inc.View 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.

ITS61869

ELECTRICAL SYSTEM; FUEL/PROPULSION SYSTEM

Instructions to accommodate customer requests to add H2 tank pressure and tank temperature gauge on dash as visible metric for H2 fuel testing requirement.

ITS61772

ELECTRICAL SYSTEM

Instructions for uploading the latest software version. When the Voltage Regulator frequency on the PWM enable signal is not 500hz, the regulator can cause CAN errors on whatever CAN line it is installed onto, causing some programming procedures to fail.

ITS61748

ELECTRICAL SYSTEM

Instructions for verifying/correcting torque on front destination sign mounting hardware installed on certain buses.

ITS61712

FUEL/PROPULSION SYSTEM

This ITS provides instructions on how to replace the air intake assembly on certain fuel cells. This is required due to the air filter for the original intake has been obsoleted by the supplier.

ITS61621

SUSPENSION

Instructions to verify the upper shock absorber mount hardware is torqued to spec.

260313-XHE coolant leak

FUEL/PROPULSION SYSTEM

Email/letter to customers regarding a coolant leak on some fuel-cell buses.

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 XHE40 by model year
YearComplaintsRecallsInvestigationsIssue Index
2026020—
2025Viewing030—
2024040—
2023040—
2022010—
2021010—
2020000—
2019020—
2018020—
2017010—
2016020—

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.