Recall 23V722 affects 2,351 2019-2024 New Flyer XD35, XD40, XN35, and XN40 transit buses for driveshaft separation. Repair is free through New Flyer.
New Flyer is recalling 2,351 2019-2024 XN40, XN35, XD35, and XD40 transit buses because the transmission yoke can separate and let the driveshaft come apart. A sudden loss of drive power can raise crash risk, and New Flyer dealers will complete the recall repair free of charge.
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What's wrong?
On affected 2019-2024 New Flyer XN40, XN35, XD35, and XD40 buses, the transmission yoke connects the transmission output shaft to the driveshaft. The driveshaft carries power from the transmission toward the drive axle, so the yoke has to stay clamped tightly while the bus starts, stops, and shifts.
The problem is the output yoke bolt on certain Allison B400R or B3400xFE_R transmissions. If that bolt loosens, the yoke can separate from the transmission output shaft. Once the yoke separates, the driveshaft can separate too, and the bus can suddenly lose drive power.
New Flyer says transit bus duty cycles create heavy start, stop, and shift activity at this bolted joint. The filing says the failure can occur with warning, but it does not name a specific warning sign. Treat any change in driveline behavior as a reason to take the bus out of service and have the transmission yoke inspected.
Who's affected?
Spans 4 New Flyer bus models across 6 model years, all tied to the driveline.
| 2020 New Flyer XN40 | driveline |
|---|---|
| 2024 New Flyer XN40 | driveline |
| 2024 New Flyer XN35 | driveline |
| 2023 New Flyer XN40 | driveline |
| 2020 New Flyer XN35 | driveline |
| 2021 New Flyer XN35 | driveline |
| 2021 New Flyer XN40 | driveline |
| 2019 New Flyer XN35 | driveline |
| 2019 New Flyer XD35 | driveline |
| 2019 New Flyer XD40 | driveline |
| 2019 New Flyer XN40 | driveline |
| 2020 New Flyer XD35 | driveline |
| 2020 New Flyer XD40 | driveline |
| 2021 New Flyer XD40 | driveline |
| 2021 New Flyer XD35 | driveline |
| 2022 New Flyer XN35 | driveline |
| 2022 New Flyer XN40 | driveline |
| 2022 New Flyer XD35 | driveline |
| 2022 New Flyer XD40 | driveline |
| 2024 New Flyer XD40 | driveline |
| 2023 New Flyer XD40 | driveline |
| 2023 New Flyer XN35 | driveline |
| 2023 New Flyer XD35 | driveline |
| 2024 New Flyer XD35 | driveline |
| Units affected | 2,351 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching year and model does not confirm inclusion. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
A sudden loss of drive power leaves the bus without propulsion and increases the risk of a crash. If warning signs appear or drive power drops, move out of traffic when safe and arrange service before returning the vehicle to route use. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2019-2024 New Flyer XN40, XN35, XD35, or XD40 bus is included in this recall.
- Contact a franchised New Flyer dealer to schedule the free transmission-yoke-bolt inspection and tightening that addresses driveshaft separation and sudden loss of drive power.
- Bring the owner letter if New Flyer mailed one. If not, reference recall number 23V722 when you call.
- Remove the bus from service if it loses drive power, and contact New Flyer before moving it.
What happens at the repair
At the dealer, a New Flyer technician works with Allison Transmission to inspect the transmission yoke bolts and tighten any that are loose. The inspection and bolt tightening are free under the recall, with parts and labor covered. New Flyer's general reimbursement plan covers documented out-of-pocket repairs tied to this recall. If you already paid for a related transmission or driveshaft repair before the notice, ask New Flyer customer service how to submit documentation under that plan.
| Reimbursement | Reimbursement available |
|---|
Timeline
| October 26, 2023 | NHTSA published the recall |
|---|---|
| November 30, 2023 | Dealer notification began |
| November 30, 2023 | Dealer notification ended |
| November 30, 2023 | Interim owner notification (was planned for this date) |
| December 9, 2023 | Owner notification mailed |
Frequently asked questions
What is recall 23V722?
Recall 23V722 covers 2,351 2019-2024 New Flyer XD35, XD40, XN35, and XN40 transit buses. The transmission yoke bolts can loosen, allowing the yoke and driveshaft to separate and causing a sudden loss of drive power. New Flyer and Allison Transmission will inspect and tighten the bolts for free.
What should I do if my 2019-2024 New Flyer XN40, XN35, XD35, or XD40 is on this recall?
Check your VIN to confirm whether your specific bus is included in recall 23V722. If it is, contact New Flyer customer service at 1-800-241-2947 and reference recall R23-20. New Flyer will coordinate the inspection and any needed transmission yoke bolt tightening at no charge.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and New Flyer's remedy says the inspection and any needed tightening of loose transmission yoke bolts are free of charge. The work is coordinated with Allison Transmission.
What is the safety risk?
The safety risk is sudden loss of drive power. If the transmission yoke separates and the driveshaft separates, the bus can lose propulsion while in service, increasing crash risk. Recall 23V722 does not carry a do-not-drive order, but included buses need the free inspection and repair.
When were owners notified about recall 23V722?
Owner notification letters were mailed December 9, 2023. If your agency or fleet did not receive a letter, the VIN still decides whether the bus is included. Use the VIN check, then contact New Flyer customer service and reference recall R23-20.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/23V722000 |
|---|---|
| New Flyer customer service | 1-800-241-2947 |
| NHTSA recall # | 23V722 |
| NHTSA recall # (full) | 23V722000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Report (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Recall Acknowledgement (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 →