Recall 25V053 affects 210 2023-2024 New Flyer XDE60, XD60, XD40, and XD35 buses for fuel-hose leaks. Repair is free at any franchised New Flyer dealer.
New Flyer is recalling 210 transit buses, including 2023-2024 XDE60 and 2024 XD60, XD40, and XD35 models, because remote fuel filter hoses can separate from their fittings and cause a fuel leak or engine stall. The defect raises the risk of fire near an ignition source and the risk of a crash; New Flyer dealers will complete the repair free of charge.
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What's wrong?
The affected 2023-2024 New Flyer XDE60, XD60, XD40, and XD35 transit buses use Cummins L9 diesel engines with a remote Stage 2 fuel filter. That filter uses pressurized fuel hoses with quick-connect fittings to carry diesel fuel through the engine's fuel system. Those hoses are supposed to stay locked to the fitting while fuel is under pressure.
On the affected buses, a hose from batch code 518220 can separate from its fitting. When that happens, diesel fuel leaks and the engine can stall. A stall in traffic raises the risk of a crash, and leaked fuel near an ignition source raises the risk of a fire.
Operators or people near the bus can see smoke or other visible signs of a fuel leak. They can also smell diesel fuel before the problem becomes more serious.
Who's affected?
The scope spans four New Flyer bus models across the 2023-2024 model years, all tied to the same fuel hose component.
| 2023 New Flyer XDE60 | fuel system |
|---|---|
| 2024 New Flyer XD60 | fuel system |
| 2024 New Flyer XD40 | fuel system |
| 2024 New Flyer XD35 | fuel system |
| 2024 New Flyer XDE60 | fuel system |
| Units affected | 210 |
| 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?
A fuel leak near an ignition source increases fire risk, and an engine stall increases crash risk. Smoke, visible fuel leakage, or diesel odor around the bus means the vehicle needs prompt service attention. Schedule the recall repair soon and keep operators alert for those signs. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2023-2024 New Flyer XDE60, XD60, XD40, or XD35 bus is included in this recall.
- Contact a franchised New Flyer dealer to schedule the free remote-fuel-filter hose replacement that fixes the fuel-leak and stall risk.
- Bring the recall notice if you have it, and reference recall number 25V053 when you call.
- Call Cummins customer service at 1-800-286-6467 with engine-related questions before the repair.
- Watch for fuel odor, visible fuel, or stalling, and remove the bus from service until New Flyer or the dealer gives repair instructions.
What happens at the repair
At the dealer, a New Flyer technician replaces the fuel hoses covered by recall 25V053. The repair is available now, and parts and labor are free under the recall. Owner letters were mailed March 11, 2025, so the service desk can confirm the campaign when you schedule. Out-of-pocket fuel hose repairs before the owner letter are handled through the manufacturer's limited warranty, not through a separate reimbursement program. Ask the service desk how warranty coverage applies if you have prior repair paperwork.
| Reimbursement | Warranty coverage applies |
|---|
Timeline
| February 3, 2025 | NHTSA published the recall |
|---|---|
| February 9, 2025 | Dealer notification began |
| February 9, 2025 | Dealer notification ended |
| March 11, 2025 | Owner notification mailed |
| March 11, 2025 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
| March 11, 2025 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 25V053?
Recall 25V053 covers 210 2023-2024 New Flyer XDE60, XD60, XD40, and XD35 transit buses with Cummins L9 diesel engines. The remote fuel filter hoses can separate from the fitting, causing a fuel leak and an engine stall. Cummins will replace the fuel hoses for free.
What should I do if my 2023-2024 New Flyer XDE60, XD60, XD40, or XD35 is on this recall?
Check your VIN to confirm the specific bus is included in recall 25V053. If it is, contact Cummins customer service at 1-800-286-6467 or New Flyer customer service at 1-800-241-2947 to arrange the free fuel hose replacement.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and Cummins will replace the affected fuel hoses free of charge. Parts and labor are covered for buses included in recall 25V053.
What is the safety risk?
The safety risk is a fuel leak and an engine stall. A fuel leak near an ignition source increases fire risk, and an engine stall increases crash risk. If your VIN is included, arrange the free fuel hose replacement before returning the bus to regular service.
When were owners notified about recall 25V053?
Owner notification letters were mailed March 11, 2025. If you operate or recently acquired one of these New Flyer buses and never received a letter, check your VIN and reference recall 25V053 when contacting Cummins or New Flyer customer service.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V053000 |
|---|---|
| New Flyer customer service | 1-800-286-6467 |
| NHTSA recall # | 25V053 |
| NHTSA recall # (full) | 25V053000 |
Source documents
-
Download Recall Document (PDF) (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 19, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →