Recall 20V462 covers 164 2015-2016 New Flyer XDE60, XDE40, and XDE35 buses for drive-unit pressure-switch failure. Repair is free at any franchised New Flyer dealer.
New Flyer is recalling 164 2015-2016 XDE60, XDE40, and XDE35 transit buses because pressure switches on certain Allison Transmission drive units can fail and cause a loss of drive. An unexpected disabled bus increases crash risk and creates injury risk when passengers are moved to another bus; New Flyer dealers will complete the free repair.
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What's wrong?
The C1/C2 pressure switches in the Allison hybrid drive unit on 2015-2016 New Flyer XDE60, XDE40, and XDE35 buses help the transmission control hydraulic pressure inside the drive system. That pressure lets the unit apply the right internal clutches so engine and electric power move through the power train to the wheels.
On affected buses, the pressure switches were built with recycled resin material instead of the specified material. That manufacturing issue can cause the switch to fail and give the drive unit the wrong pressure information. When that happens, the hybrid drive unit can stop delivering power, and the bus can lose drive.
Operators can see ATI diagnostic trouble codes before the switch failure leads to a loss of drive. Treat those codes as the warning sign, and give the dealer or service technician the Allison hybrid drive unit and C1/C2 pressure switch information when arranging the recall repair.
Who's affected?
The scope spans XDE35, XDE40, and XDE60 buses from the 2015-2016 model years, all tied to the automatic transmission pressure switch.
| 2015 New Flyer XDE60 | automatic transmission |
|---|---|
| 2015 New Flyer XDE40 | automatic transmission |
| 2016 New Flyer XDE40 | automatic transmission |
| 2016 New Flyer XDE60 | automatic transmission |
| 2016 New Flyer XDE35 | automatic transmission |
| Units affected | 164 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
A loss of drive can disable the bus unexpectedly and increase crash risk. Moving passengers to another bus after a failure also raises injury risk during the transfer. ATI diagnostic trouble codes are the warning sign listed for this recall, so treat them as a reason to schedule service soon. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2015-2016 New Flyer XDE60, XDE40, or XDE35 transit bus is included in this recall.
- Contact New Flyer customer service at 1-204-224-6706 to schedule the free Allison hybrid-drive pressure-switch replacement.
- Ask the service team to inspect and clear debris in the pressure-switch plumbing, which addresses the pressure-switch failure that can cause loss of drive.
- Reference recall number 20V462 and New Flyer recall R20-007 when you call.
- Bring the recall notice if New Flyer mailed one to your fleet.
- Keep the bus out of passenger service until New Flyer or Allison completes the free repair.
What happens at the repair
At the dealer, a New Flyer technician works with Allison Transmissions to remove and replace the C1 and C2 pressure switches on each hybrid drive motor. They also inspect the related pressure switch plumbing and clear or correct debris accumulation. Parts and labor are covered under the recall. New Flyer has a general reimbursement plan on file for owners who already paid for a related repair before the notice. Keep repair documentation and contact New Flyer customer service at 1-204-224-6706 to ask how to submit the claim.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 6, 2020 | NHTSA published the recall |
|---|---|
| August 17, 2020 | Dealer notification began |
| August 17, 2020 | Dealer notification ended |
| August 17, 2020 | Owner notification mailed |
| August 17, 2020 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 20V462?
Recall 20V462 covers 164 2015-2016 New Flyer XDE60, XDE40, and XDE35 transit buses with specific Allison Transmission drive units. The C1 and C2 pressure switches can fail, causing loss of drive. New Flyer will have the pressure switches replaced and related plumbing inspected for debris free of charge.
What should I do if my 2015-2016 New Flyer XDE60, XDE40, or XDE35 is on this recall?
Check your VIN to confirm your specific bus is included in recall 20V462. If it is, contact New Flyer customer service at 1-204-224-6706 or your New Flyer service contact to arrange the Allison Transmission pressure-switch repair. Reference recall R20-007 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and New Flyer's remedy states that the C1 and C2 pressure switches will be removed and replaced free of charge. The related debris inspection and correction in the pressure-switch plumbing are also covered.
What is the safety risk in recall 20V462?
The safety risk is unexpected loss of drive. In recall 20V462, that loss of drive can disable the transit bus and increase crash risk. If passengers need to be offloaded and transferred to another bus, that transfer can also increase injury risk.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/20V462000 |
|---|---|
| New Flyer customer service | 1-204-224-6706 |
| NHTSA recall # | 20V462 |
| NHTSA recall # (full) | 20V462000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Quarterly Report (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 24, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →