Recall 16V678 affects 38 2016 New Flyer XN60 and XN40 buses for CNG PRD failure. Do not drive. Free repair at a New Flyer dealer.
An unexpected CNG gas release near an ignition source increases the risk of a fire. There is no warning sign before failure, and the reported failures happened during refueling. Do not drive or operate the bus until the recall remedy is applied. Arrange service before returning it to route use. Repair is free at any franchised New Flyer dealer.
New Flyer is recalling 38 2016 XN60 and XN40 transit buses because the pressure relief device in the CNG system can fracture and separate, releasing high-pressure CNG. Do not drive an included bus until a New Flyer dealer completes the free repair, since gas released near an ignition source increases the risk of a fire.
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What's wrong?
The 2016 New Flyer XN60 and XN40 use a compressed natural gas fuel system, which stores fuel under high pressure in roof-mounted cylinders. A pressure relief device, or PRD, is a safety valve in that system. It is there to release gas in a controlled way when pressure or temperature reaches unsafe levels. Vent tubing routes that released gas away from the bus.
On affected buses, the newer CNG fuel system used stainless steel vent tubing that did not give the fuel cylinders enough strain relief as they expanded and contracted. During refueling, that movement put excessive force into the PRD. The threaded base of the PRD fractured where it attached to the solenoid valve body, and the device separated, allowing a high-pressure release of CNG.
There is no warning sign before failure. The failures described by New Flyer happened while the bus was being refueled, when the fuel tanks were expanding.
Who's affected?
Covers the XN60 and XN40 bus models built from June 22, 2016 to September 14, 2016, both involving the fuel system.
| 2016 New Flyer XN60 | fuel system |
|---|---|
| 2016 New Flyer XN40 | fuel system |
| Units affected | 38 |
| Field incidents | NHTSA has logged 2 field incidents to date. |
A matching 2016 New Flyer XN60 or XN40 bus does not guarantee inclusion. Check your VIN to confirm whether this recall applies to your specific bus.
What's the safety risk?
An unexpected CNG gas release near an ignition source increases the risk of a fire. There is no warning sign before failure, and the reported failures happened during refueling. Do not drive or operate the bus until the recall remedy is applied. Arrange service before returning it to route use. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2016 New Flyer XN60 or XN40 is included in this recall.
- Do not drive the bus until the CNG pressure relief device repair is complete.
- Arrange a tow if the bus must be moved for repair; do not drive it there yourself.
- Contact a franchised New Flyer dealer to schedule the free vent tubing system installation and PRD replacement that addresses the high pressure CNG release risk.
- Bring the recall notice if New Flyer sent one. If not, reference recall number 16V678 and New Flyer recall R16-026 when you call.
What happens at the repair
At the dealer, a New Flyer technician installs a new vent tubing system for the compressed natural gas system and replaces the pressure relief device. The recall repair is available, and parts and labor are free. Keep the bus out of operation until the remedy is applied. New Flyer's general reimbursement plan is on file for owners who already paid for a related repair. Contact New Flyer customer service or ask the service desk what documentation they need for a reimbursement claim.
| Reimbursement | Reimbursement available |
|---|
Timeline
| September 19, 2016 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
|---|---|
| September 19, 2016 | Interim owner notification (was planned for this date) |
| September 20, 2016 | NHTSA published the recall |
| September 28, 2016 | Owner notification mailed |
Frequently asked questions
What is recall 16V678?
Recall 16V678 covers 38 2016 New Flyer XN60 and XN40 Xcelsior transit buses powered by CNG. The pressure relief device in the CNG system can fracture and separate, causing a high-pressure CNG release. New Flyer dealers will replace the PRD and install new vent tubing for free.
What should I do if my 2016 New Flyer XN60 or XN40 is on this recall?
Check your VIN to confirm whether your specific bus is included in recall 16V678. If it is included, Do not drive it or keep it in service. Contact New Flyer customer service at 1-204-224-6706 or a franchised New Flyer dealer to arrange the free remedy.
Does the New Flyer recall repair cost anything?
No. Federal recall law requires the manufacturer to provide the recall repair at no cost. New Flyer dealers will install a new vent tubing system and replace the pressure relief device free of charge.
What does do not drive mean for recall 16V678?
Do not drive means the affected bus should be removed from operation until the recall repair is complete. The issue involves an unexpected CNG release, and CNG gas near an ignition source increases fire risk. Ask New Flyer or the dealer how to move the bus safely if service is needed.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V678000 |
|---|---|
| New Flyer customer service | 1-204-224-6706 |
| NHTSA recall # | 16V678 |
| NHTSA recall # (full) | 16V678000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →