Recall 23V540 affects 13 2022-2023 Nova Bus Lfs transit buses for high-voltage battery short-circuit risk. Repair is free at any franchised Nova Bus dealer.
Nova Bus is recalling 13 2022-2023 Lfs battery electric transit buses because rivnut threaded inserts inside the high-voltage battery can be over-tightened and break. A resulting electrical short circuit increases the risk of a fire, and Nova Bus dealers will complete the repair free of charge.
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What's wrong?
The high-voltage battery pack on 2022-2023 Nova Bus Lfs battery electric transit buses stores the electricity that drives the propulsion system. Inside the pack, bus-bars connect battery modules so power moves through the pack in a controlled path. Threaded rivnut inserts hold those internal connections in place.
On affected buses, rivnut threaded inserts inside the battery pack were over-tightened during supplier assembly or rework. That poor torque control can break the inserts or the bus-bar connection hardware. A broken connection inside a high-voltage pack can create a short circuit, which can start a contained thermal event in the battery pack.
If a battery thermal event is developing while the bus is operating or charging, the thermal runaway detection warning light for the driver will illuminate. Safely stop the bus and park it outside, away from property.
Who's affected?
This is a narrow bus recall: one model across two model years, with the same high-voltage traction battery component named for each year.
| 2022 Nova Bus Lfs | high-voltage traction battery |
|---|---|
| 2023 Nova Bus Lfs | high-voltage traction battery |
| Units affected | 13 |
| Field incidents | NHTSA has logged no 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?
An electrical short circuit raises the risk of fire. If the thermal runaway warning light comes on while the bus is in operation or charging, safely stop, move it outside away from property, and contact the dealer before returning it to service. Repair is free at any franchised Nova Bus dealer.
What should I do?
- Check your VIN to confirm your 2022-2023 Nova Bus Lfs is included in this recall.
- Contact a franchised Nova Bus dealer to schedule the free high-voltage battery replacement that addresses the rivnut short-circuit fire risk.
- Reference recall number 23V540 and Nova Bus recall CR5461 when you call.
- Bring the owner letter if your fleet received one; parts and labor are covered.
- Ask Nova Bus service how to handle charging and storage until the battery replacement is complete.
What happens at the repair
At the dealer, a Nova Bus technician replaces the high-voltage batteries covered by the recall. The battery replacement is free of charge, with parts and labor covered under the recall. If the bus already had this battery repair completed at owner expense, the Nova Bus standard reimbursement plan applies. Ask Nova Bus customer service or the service desk what documentation they need for a reimbursement review.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 2, 2023 | NHTSA published the recall |
|---|---|
| August 31, 2023 | Dealer notification began |
| August 31, 2023 | Dealer notification ended |
| August 31, 2023 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| August 31, 2023 | Interim owner notification (was planned for this date) |
| September 5, 2023 | Owner notification mailed |
Frequently asked questions
What is recall 23V540?
Recall 23V540 covers 13 2022-2023 Nova Bus Lfs battery electric transit buses with rivnut threaded inserts inside the high-voltage battery that can be over-tightened and break, resulting in a short circuit. An electrical short circuit increases fire risk. Nova Bus will replace the batteries for free.
What should I do if my 2022-2023 Nova Bus Lfs is on this recall?
Check your VIN to confirm your specific bus is included in recall 23V540. If it is, contact Nova Bus customer service at 1-800-350-6682 or your authorized Nova Bus service contact to arrange the free battery replacement. Reference Nova Bus recall number CR5461 when you call.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and Nova Bus will replace the affected high-voltage batteries free of charge. Parts and labor are covered for buses included in recall 23V540.
What is the safety risk?
The safety risk is fire. The recall filing says the high-voltage battery inserts can break and cause an electrical short circuit, which increases the risk of a fire. Confirm the VIN, then arrange the free battery replacement through Nova Bus or an authorized service contact.
When were owners notified about recall 23V540?
Nova Bus mailed owner notification letters on September 5, 2023. If your fleet or agency did not receive a letter, check the VIN for each 2022-2023 Nova Bus Lfs and reference recall 23V540 or Nova Bus recall CR5461 when contacting service.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/23V540000 |
|---|---|
| Nova Bus customer service | 1-800-350-6682 |
| NHTSA recall # | 23V540 |
| NHTSA recall # (full) | 23V540000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notice (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Acknowledgement (PDF)
- Download Recall Report (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 →