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Campaign 21V365 Posted May 18, 2021 3,600 units

2016-2021 New Flyer XD/XDE Recall 21V365: Fuel Rail

RN
Reviewed by the RecallNotify editorial team
Published May 23, 2026

Recall 21V365 covers 3,600 2016-2021 New Flyer XD and XDE vehicles for a fuel-rail leak. Repair is free at any franchised New Flyer dealer.

New Flyer is recalling 3,600 2016-2021 XD35, XD60, XD40, XDE60, XDE40, and XDE35 vehicles because a sealing washer can fail to seat correctly in high-pressure fuel rail pilot bore holes. A fuel leak near an ignition source increases the risk of fire, and the New Flyer dealer repair is free.

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What's wrong?

The fuel rail on 2016-2021 New Flyer XD35, XD60, XD40, XDE60, XDE40, and XDE35 buses is part of the Cummins L9 diesel engine. It holds diesel fuel under pressure and feeds it to the engine's injectors. The sealing washer at the end of the rail helps keep that pressurized fuel inside the joint.

On affected engines, the pilot bore for that sealing washer is too small. That fit keeps the washer from sitting correctly in the fuel rail. Without the right seating load, the joint does not stay sealed during service, and diesel fuel leaks from the high pressure fuel rail assembly.

The warning signs are direct. An operator can see diesel fuel, smell diesel fuel, or see the check engine lamp come on. Any of those signs point to a fuel rail leak that needs dealer service.

Who's affected?

Covers XD35, XD40, XD60, XDE35, XDE40, and XDE60 buses across 2016-2021, all tied to the Cummins L9 diesel fuel rail.

2021 New Flyer XD35 fuel system
2021 New Flyer XD60 fuel system
2021 New Flyer XD40 fuel system
2020 New Flyer XD60 fuel system
2020 New Flyer XD40 fuel system
Units affected3,600
Field incidentsNHTSA 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 diesel fuel leak near an ignition source increases the risk of a fire. If the operator sees or smells diesel fuel, or the check engine lamp illuminates, stop using the bus and arrange service. Repair is free at any franchised New Flyer dealer.

What should I do?

  1. Check your VIN to confirm your 2016-2021 New Flyer XD35, XD60, XD40, XDE60, XDE40, or XDE35 is included in this recall.
  2. Contact a franchised New Flyer dealer to schedule the free fuel-rail inspection and rail replacement that fixes the washer seating problem behind the fuel leak risk.
  3. Bring the owner letter if New Flyer mailed one, or reference recall number 21V365 when you call.
  4. Keep the bus away from ignition sources if you smell fuel or see a fuel leak, and have the dealer advise before moving it.
  5. Call New Flyer customer service at 1-204-224-6706 with questions about scheduling or the repair.

What happens at the repair

At the dealer, a New Flyer technician inspects the rail threads in the high pressure fuel rail assembly and replaces the rail as needed. The recall repair is free, with parts and labor covered. New Flyer's general reimbursement plan is on file for owners who already paid for a related repair before the recall notice. Bring repair invoices, proof of payment, and any fuel rail repair paperwork to the service desk so the claim can be handled under that plan.

ReimbursementReimbursement available

Timeline

May 18, 2021 NHTSA published the recall
June 21, 2021 Dealer notification began
June 21, 2021 Dealer notification ended
June 21, 2021 Interim owner notification (was planned for this date)
June 28, 2021 Owner notification mailed

Frequently asked questions

What is recall 21V365?

Recall 21V365 covers 3,600 2016-2021 New Flyer XD35, XD60, XD40, XDE60, XDE40, and XDE35 buses with high pressure fuel rail sealing washers that fail to seat correctly, allowing fuel to leak. New Flyer will inspect the rail threads and replace the rail as needed for free.

What should I do if my 2016-2021 New Flyer XD35, XD60, XD40, XDE60, XDE40, or XDE35 is on this recall?

Check your VIN to confirm the bus is included in recall 21V365. If it is, contact New Flyer service or a franchised New Flyer dealer to schedule the fuel rail inspection. Reference recall number 21V365 when you call. The repair is free.

Is the recall repair free?

Yes. Federal recall law requires manufacturers to repair safety defects at no cost, and New Flyer will inspect the rail threads and replace the rail as needed free of charge. Parts and labor are covered for vehicles included in recall 21V365.

What is the safety risk?

A fuel leak near an ignition source increases the risk of a fire. The defect involves sealing washers at the high pressure fuel rail assembly. If your VIN is included, arrange the free inspection and any needed rail replacement before returning the bus to regular service.

When were owners notified about recall 21V365?

New Flyer mailed owner notification letters on June 28, 2021. If your fleet did not receive a letter, check the VIN and call New Flyer customer service at 1-204-224-6706 with recall number 21V365.

More information

NHTSA campaign pagenhtsa.gov/vehicle-recalls/21V365000
New Flyer customer service1-204-224-6706
NHTSA recall #21V365
NHTSA recall # (full)21V365000

Source documents

This article is generated from NHTSA's primary recall filings and reviewed against the source on May 23, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →