Recall 22V637 affects 55 2021-2022 New Flyer transit buses for steering gear fractures. Repair is free at any franchised New Flyer dealer.
New Flyer is recalling 55 2021-2022 XD40, XD60, XDE40, XN35, XE40, XN40, and XN60 transit buses because incorrectly assembled steering gears can fracture. A fractured steering gear can cause loss of steering control and increase crash risk; New Flyer dealers will complete the free repair.
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What's wrong?
The Sheppard Model M110P steering gear is the steering box on these 2021-2022 New Flyer XD40, XE40, XN40, XN35, XD60, XDE40, and XN60 transit buses. It turns the driver's steering input into movement at the wheels, with recirculating balls inside the gear helping the mechanism move under load.
During assembly, the ball insertion operation missed some of those internal balls. Later rework and inspection did not catch the missing pieces. With too few recirculating balls inside the gear, the load is not carried the way the gear was designed to carry it. The steering gear can fracture.
The driver can feel steering that seems strained before the gear fails. There is no audible alert or dashboard warning light, so that heavier steering feel is the warning sign to take seriously.
Who's affected?
Covers seven bus models across the 2021 and 2022 model years, all tied to the steering system.
| 2021 New Flyer XD40 | steering system |
|---|---|
| 2022 New Flyer XD40 | steering system |
| 2022 New Flyer XE40 | steering system |
| 2022 New Flyer XN40 | steering system |
| 2022 New Flyer XN35 | steering system |
| 2022 New Flyer XD60 | steering system |
| 2022 New Flyer XDE40 | steering system |
| 2021 New Flyer XN60 | steering system |
| 2021 New Flyer XDE40 | steering system |
| 2021 New Flyer XD60 | steering system |
| Units affected | 55 |
| 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 this recall applies to your specific bus.
What's the safety risk?
A fractured steering gear can lead to loss of steering control and increase the risk of a crash. If the steering feels strained or harder than normal, stop using the vehicle and contact a New Flyer dealer for inspection. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2021-2022 New Flyer XD40, XE40, XN40, XN35, XD60, XDE40, or XN60 transit bus is included in this recall.
- Contact a franchised New Flyer dealer to schedule the free steering-gear inspection and replacement if required. The inspection checks for an incorrectly assembled steering gear that can fracture.
- Bring the recall notice if you have it, and reference recall number 22V637 when you call.
- Limit operation until the inspection is complete, because a fractured steering gear can cause loss of steering control.
What happens at the repair
At the dealer, a New Flyer technician inspects the steering gear and replaces it if the inspection shows replacement is required. The recall repair is available now, and parts and labor are free. New Flyer uses its general reimbursement plan on file for this recall. Owners who already paid for a steering gear repair tied to this issue should contact New Flyer customer service with repair documentation and receipts so the prior repair can be reviewed under that plan.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 24, 2022 | NHTSA published the recall |
|---|---|
| September 2, 2022 | Owner notification mailed |
| October 17, 2022 | Dealer notification began |
| October 17, 2022 | Dealer notification ended |
| October 17, 2022 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| October 17, 2022 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 22V637?
Recall 22V637 covers 55 2021-2022 New Flyer XD40, XD60, XDE40, XN35, XE40, XN40, and XN60 transit buses with steering gears that were incorrectly assembled. The gear can fracture, causing loss of steering control and increasing crash risk.
What should I do if my 2021-2022 New Flyer XD40, XD60, XDE40, XN35, XE40, XN40, or XN60 is on this recall?
Check your VIN to confirm your specific bus is included in recall 22V637. If it is, contact a New Flyer dealer to schedule the steering gear inspection. The dealer will replace the steering gear if required, free of charge. Reference recall R22-026 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost. New Flyer dealers will inspect the steering gear and replace it if required, free of charge.
What is the safety risk?
The safety risk is loss of steering control. New Flyer's filing says an incorrectly assembled steering gear can fracture, which can make the bus harder or impossible to steer and increase crash risk. If your VIN is included, arrange the free dealer inspection.
When were owners notified about recall 22V637?
New Flyer mailed owner notification letters on September 2, 2022. If you manage or own one of these buses and did not receive a letter, check your VIN and contact New Flyer customer service at 1-204-224-6706 with recall number R22-026.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/22V637000 |
|---|---|
| New Flyer customer service | 1-204-224-6706 |
| NHTSA recall # | 22V637 |
| NHTSA recall # (full) | 22V637000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Recall Acknowledgement (PDF)
- Download Recall Report (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Document (PDF) (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →