NHTSA Campaign 25V566000
ELECTRICAL SYSTEM:PROPULSION SYSTEM:TRACTION BATTERY:MANAGEMENT SYSTEM/ENERGY CONTROL MODULE (BMS/BECM):SOFTWARE
Issued by New Flyer of America, Inc. · Reported Aug 29, 2025 · 1,170 vehicles affected
What's wrong
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.
Vehicles affected by this recall
| Make | Model | Year | Units |
|---|---|---|---|
| NEW FLYER | XE35 | 2019 | 1,170 |
| NEW FLYER | XE35 | 2020 | 1,170 |
| NEW FLYER | XE35 | 2021 | 1,170 |
| NEW FLYER | XE35 | 2022 | 1,170 |
| NEW FLYER | XE35 | 2023 | 1,170 |
| NEW FLYER | XE35 | 2024 | 1,170 |
| NEW FLYER | XE35 | 2025 | 1,170 |
| NEW FLYER | XE40 | 2013 | 1,170 |
| NEW FLYER | XE40 | 2017 | 1,170 |
| NEW FLYER | XE40 | 2018 | 1,170 |
| NEW FLYER | XE40 | 2019 | 1,170 |
| NEW FLYER | XE40 | 2020 | 1,170 |
| NEW FLYER | XE40 | 2021 | 1,170 |
| NEW FLYER | XE40 | 2022 | 1,170 |
| NEW FLYER | XE40 | 2023 | 1,170 |
| NEW FLYER | XE40 | 2024 | 1,170 |
| NEW FLYER | XE40 | 2025 | 1,170 |
| NEW FLYER | XE60 | 2019 | 1,170 |
| NEW FLYER | XE60 | 2020 | 1,170 |
| NEW FLYER | XE60 | 2021 | 1,170 |
| NEW FLYER | XE60 | 2022 | 1,170 |
| NEW FLYER | XE60 | 2023 | 1,170 |
| NEW FLYER | XE60 | 2024 | 1,170 |
| NEW FLYER | XE60 | 2025 | 1,170 |
| NEW FLYER | XHE40 | 2023 | 1,170 |
| NEW FLYER | XHE40 | 2024 | 1,170 |
| NEW FLYER | XHE40 | 2025 | 1,170 |
| NEW FLYER | XHE60 | 2024 | 1,170 |
| NEW FLYER | XHE60 | 2025 | 1,170 |
Source: NHTSA Campaign 25V566000 on nhtsa.gov. To check the current repair status for a specific vehicle, use our free VIN decoder.