Recall 24V425 affects 27 2023 New Flyer XD35, XD40, and XD60 buses for separating fuel filter hoses. Free repair at franchised New Flyer dealers.
New Flyer is recalling 27 2023 XD35, XD40, and XD60 vehicles equipped with certain Cummins L9 diesel engines because remote fuel filter hoses can separate from their fittings. A fuel leak near an ignition source increases the risk of fire, and loss of fuel supply can stall the engine; New Flyer dealers will complete the repair free of charge.
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What's wrong?
The remote fuel filter hoses on the 2023 New Flyer XD35, XD40, and XD60 buses carry diesel fuel through the Cummins L9 engine's fuel filter setup. These fuel carrying hoses use quick connect fittings, and they feed pressurized fuel through the remote Stage 2 fuel filter system so the engine keeps a steady fuel supply.
On the recalled buses, the hose connector was not crimped tightly enough. That weak crimp can let the hose separate from its fitting. If the hose separates, diesel fuel can leak, and the engine can lose the fuel supply it needs to keep running.
A driver, technician, or person near the bus can notice smoke, visible fuel leakage, or the smell of diesel fuel. Those are warning signs that the hose connection has failed or is starting to leak.
Who's affected?
Covers XD35, XD40, and XD60 buses, all tied to the same fuel hose with quick connect fittings.
| 2023 New Flyer XD35 | fuel system |
|---|---|
| 2023 New Flyer XD40 | fuel system |
| 2023 New Flyer XD60 | fuel system |
| Units affected | 27 |
| Field incidents | NHTSA has logged no field incidents to date. |
A matching 2023 New Flyer XD35, XD40, or XD60 model does not guarantee inclusion. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
A fuel leak near an ignition source increases fire risk. Loss of fuel also can stall the engine and increase crash risk. If anyone sees smoke, visible fuel leakage, or smells diesel fuel, stop service and contact the dealer before further operation. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2023 New Flyer XD35, XD40, or XD60 is included in this recall.
- Contact New Flyer customer service at 1-800-241-2947 to schedule the free Cummins fuel-filter-hose replacement that fixes the fuel leak and fuel-supply loss.
- Reference recall number 24V425 when you call or schedule service.
- Bring the recall notice if New Flyer mailed one.
- Watch for fuel odor, visible leaking fuel, or engine stalling, and keep the bus out of service until a service advisor gives repair instructions.
What happens at the repair
At the dealer, a New Flyer technician replaces the fuel filter hoses connected to the remote fuel filter system. The replacement parts and labor are free under the recall. Out-of-pocket repairs already paid are handled through the manufacturer's limited warranty, not through a separate reimbursement program, because New Flyer and Cummins state that any earlier product failure would have been covered by warranty. Ask the service desk how warranty coverage applies if you have prior repair paperwork.
| Reimbursement | Warranty coverage applies |
|---|
Timeline
| June 11, 2024 | NHTSA published the recall |
|---|---|
| July 21, 2024 | Dealer notification began |
| July 21, 2024 | Dealer notification ended |
| July 21, 2024 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| July 21, 2024 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 24V425?
Recall 24V425 covers 27 2023 New Flyer XD35, XD40, and XD60 buses with certain Cummins L9 diesel engines. The remote fuel filter hoses can separate from the fitting, causing a fuel leak or loss of fuel supply to the engine. Cummins will replace the fuel filter hoses for free.
What should I do if my 2023 New Flyer XD35, XD40, or XD60 is on this recall?
Check your VIN to confirm whether your specific bus is included in recall 24V425. If it is, contact New Flyer customer service at 1-800-241-2947 and reference recall 24V425. Cummins will replace the remote fuel filter hoses free of charge.
Is the recall repair free?
Yes. Federal recall law requires the defect repair to be performed at no cost to the owner. For recall 24V425, Cummins will replace the remote fuel filter hoses free of charge, and New Flyer lists 1-800-241-2947 as the customer service number for owners.
What is the safety risk?
The safety risk is fire or stalling. A fuel leak near an ignition source increases fire risk, and a lack of fuel supply can cause the engine to stall, increasing crash risk. The repair path is to have Cummins replace the affected fuel filter hoses for free.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/24V425000 |
|---|---|
| New Flyer customer service | 1-800-241-2947 |
| NHTSA recall # | 24V425 |
| NHTSA recall # (full) | 24V425000 |
Source documents
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 →