2022 NEW FLYER XE40 Complaints and Recall Information

The 2022 NEW FLYER XE40 has 0 complaints and 25 recalls filed with NHTSA. Owners most frequently report issues related to the electrical propulsion system including the traction battery and its management software, as well as steering components and vehicle speed control software defects.

The recall data reveals multiple actions affecting electrical battery systems, steering components, weight rating labels, and vehicle speed control software.

Recalls

• Traction battery defect. NHTSA recall 25V566000 affects 1170 vehicles. An inadequate weld on the high voltage battery busbar combined with incorrect software may cause the battery module to overheat, increasing fire risk. New Flyer will inspect and replace the battery module as needed and update the BMS software at no cost. Owner notification expected October 17, 2025.
• Battery pack fluid accumulation. Recall 23V083000 covers 219 vehicles. Liquid may accumulate in the battery pack enclosure, potentially causing electrical shorts and fire risk. If liquid is found, buses should not be operated and must be parked outside. Dealers will install holes and automatic drain valves free of charge. Notifications mailed May 3, 2023.
• Battery drain valve malfunction. Recall 24V056000 affects 337 vehicles. Drain valves may fail to activate properly, allowing liquid buildup in the battery pack enclosure. New Flyer will remove rubber washers from affected valves at no cost. Notification letters mailed March 14, 2024. This recall supplements 23V083000, with some vehicles requiring both repairs.
• Incorrect weight rating labels. Recall 23V711000 involves 188 vehicles. Certification labels display incorrect Gross Axle Weight and Gross Vehicle Weight Ratings, risking vehicle overloading and increased crash risk. New labels will be provided or installed free of charge. Owners notified November 9, 2023.
• Steering column defect. Recall 22V943000 includes 746 vehicles. The steering column connection to the upper shaft may loosen, leading to loss of steering control and crash risk. Dealers will replace steering column and shaft components at no cost. Owner notifications mailed February 1, 2023.
• Unintended acceleration software errors. Recall 23V898000 affects 211 vehicles. A software error may cause unintended acceleration under certain conditions, increasing crash risk. New Flyer will update the software free of charge. Notifications expected February 15, 2024.
• Unintended acceleration software errors. Separate recall 23V897000 covers 246 vehicles with a similar software defect causing unintended acceleration. Software updates will be provided at no cost. Owner notifications mailed February 13, 2024.
• Steering gear fracture risk. Recall 22V637000 covers 55 vehicles. Incorrect assembly of steering gear may cause fractures, leading to loss of steering control. Dealers will inspect and replace steering gears as needed at no charge. Owners notified September 2, 2022.

Owners of 2022 NEW FLYER XE40 buses subject to repeated steering or propulsion system defects or outstanding recall repairs may want to consult state lemon law provisions to evaluate their rights. Issues affecting safety systems and vehicle control highlight the importance of timely recall remedies.