Recall 18V394 covers 908 2014-2017 New Flyer XN60, XDE60, XD60, and XT60 buses for brake-caliper bolt breakage. Free repair at any franchised New Flyer dealer.
New Flyer is recalling 908 2014-2017 XN60, XDE60, XD60, and XT60 transit buses equipped with ZF axles and radial air disk brakes because rough guide pins in the brake calipers can break a support bolt. A broken guide pin can reduce braking ability, lengthen stopping distance, or cause loss of tire pressure, and New Flyer dealers will complete the repair free of charge.
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What's wrong?
The 2014-2017 New Flyer XN60, XDE60, XD60, and XT60 buses in this recall use radial air disc brake calipers on ZF axles. A brake caliper is the clamp that presses the brake pads against the disc when air pressure applies the brakes. Guide pins let the brake carriage move smoothly so the pads press evenly and release correctly.
On included buses, the guide pins in the center-axle Knorr-Bremse SB model calipers were made with a rough surface that was outside the intended tolerance. That rough surface adds stress to the brake carriage guide pin support bolt. Over service use, the bolt can fracture, which lets the caliper stop moving as designed and affects the air brake system's compliance with FMVSS 121.
A driver or maintenance staff can notice brake noise before the bolt fails. Uneven or tapered brake pad wear is another warning sign that the caliper is not moving correctly.
Who's affected?
Spans 4 New Flyer bus models across 2014-2017, all tied to the same brake system issue.
| 2017 New Flyer XN60 | brake system |
|---|---|
| 2017 New Flyer XDE60 | brake system |
| 2017 New Flyer XD60 | brake system |
| 2016 New Flyer XT60 | brake system |
| 2015 New Flyer XT60 | brake system |
| 2016 New Flyer XN60 | brake system |
| 2016 New Flyer XDE60 | brake system |
| 2016 New Flyer XD60 | brake system |
| 2015 New Flyer XN60 | brake system |
| 2014 New Flyer XT60 | brake system |
| 2015 New Flyer XDE60 | brake system |
| 2015 New Flyer XD60 | brake system |
| 2014 New Flyer XN60 | brake system |
| 2014 New Flyer XD60 | brake system |
| Units affected | 908 |
| Field incidents | NHTSA has logged 6 field incidents to date. |
The year and model narrow the scope, but the VIN decides. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
A broken guide pin reduces braking ability, lengthens stopping distance, or leads to tire pressure loss, which increases crash risk. Brake noise or uneven brake pad wear is a warning sign. If you notice either one, stop using the bus and arrange service. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2014-2017 New Flyer XN60, XDE60, XD60, or XT60 bus is included in this recall.
- Contact a franchised New Flyer dealer to schedule the free bushing-kit installation and brake-caliper reinstallation that addresses guide-pin bolt breakage in the radial air disk brake calipers.
- Reference recall number 18V394 and New Flyer recall R18-010 when you call.
- Bring the recall notice if New Flyer mailed one to your fleet or agency.
- Keep any affected bus out of service if braking ability changes, stopping distance increases, or tire pressure loss appears before the repair.
What happens at the repair
At the dealer, a New Flyer technician installs a bushing kit and reinstalls the radial brake calipers affected by the guide pin support bolt issue. The recall repair is free, with parts and labor covered. New Flyer has a general reimbursement plan on file for this campaign. If you've already paid for a related brake caliper repair, bring documentation to the service desk or contact New Flyer customer service to ask how to submit a claim under that plan.
| Reimbursement | Reimbursement available |
|---|
Timeline
| June 12, 2018 | NHTSA published the recall |
|---|---|
| June 25, 2018 | Dealer notification began |
| June 25, 2018 | Dealer notification ended |
| June 26, 2018 | Interim owner notification (was planned for this date) |
| June 29, 2018 | Owner notification mailed |
Frequently asked questions
What is recall 18V394?
Recall 18V394 covers 908 2014-2017 New Flyer XN60, XDE60, XD60, and XT60 transit buses with ZF radial air disk brakes. A rough guide pin surface can break a brake-caliper support bolt, reducing braking ability, increasing stopping distance, or causing tire pressure loss.
What should I do if my 2014-2017 New Flyer XN60, XDE60, XD60, or XT60 is on this recall?
Check your VIN to confirm the bus is included in recall 18V394. If it is, contact a New Flyer dealer or service representative to schedule the bushing kit installation and brake-caliper reinstallation. Reference recall number 18V394 and New Flyer recall R18-010 when you call.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to repair safety defects at no cost, and New Flyer dealers will install the bushing kit and reinstall the brake calipers free of charge. Parts and labor are covered for vehicles included in recall 18V394.
What is the safety risk in recall 18V394?
The safety risk is reduced braking ability, longer stopping distances, or loss of tire pressure. New Flyer reported that brake guide pin breakage can create those conditions and increase crash risk. The repair path is to have the bushing kit installed and the brake calipers reinstalled for free.
When did New Flyer start recall 18V394 repairs?
New Flyer began recall 18V394 on June 29, 2018. Owners with included buses can contact New Flyer customer service at 1-204-224-6706 or a New Flyer dealer, reference recall R18-010, and arrange the free brake-caliper repair.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/18V394000 |
|---|---|
| New Flyer customer service | 1-204-224-6706 |
| NHTSA recall # | 18V394 |
| NHTSA recall # (full) | 18V394000 |
Source documents
-
Download Recall Investigation Document (PDF) (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 25, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →