Recall 25V542 affects 2,354 2012-2025 New Flyer Xcelsior buses with too few or incorrectly located emergency exits. New Flyer provides free instructions and parts.
New Flyer is recalling 2,354 2012-2025 Xcelsior buses because some were built with too few emergency exits or exits in the wrong location. In an emergency, that defect can prevent or delay passengers from getting out and raise injury risk; New Flyer dealers will complete the recall repair free of charge.
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What's wrong?
The emergency exit windows on 2012-2025 New Flyer Xcelsior buses are part of the escape path for passengers and operators. These windows are designed to release from the side of the bus so people have an exit route when doors are blocked or unusable. Federal rules set how many emergency exits a bus needs and where those exits must be placed.
On affected buses, New Flyer found calculation errors in the work used to determine the required emergency egress windows under FMVSS 217. Because of those errors, certain buses were built with too few emergency exits or with exits in the wrong location for that vehicle configuration. The fix changes the window layout, such as adding emergency egress windows or moving an egress window to the other side of the bus.
There is no warning sign before failure. This is a design compliance problem, not a wear item that gives the driver a noise, light, or handling change before an evacuation route is needed.
Who's affected?
Covers Xcelsior buses from 2012-2025 that use the same side window kits for emergency exit access.
| 2012 New Flyer Xcelsior | body or structural component |
|---|---|
| 2016 New Flyer Xcelsior | body or structural component |
| 2017 New Flyer Xcelsior | body or structural component |
| 2018 New Flyer Xcelsior | body or structural component |
| 2024 New Flyer Xcelsior | body or structural component |
| 2025 New Flyer Xcelsior | body or structural component |
| 2013 New Flyer Xcelsior | body or structural component |
| 2014 New Flyer Xcelsior | body or structural component |
| 2015 New Flyer Xcelsior | body or structural component |
| 2019 New Flyer Xcelsior | body or structural component |
| 2020 New Flyer Xcelsior | body or structural component |
| 2021 New Flyer Xcelsior | body or structural component |
| 2022 New Flyer Xcelsior | body or structural component |
| 2023 New Flyer Xcelsior | body or structural component |
| Units affected | 2,354 |
| 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 your specific bus is included.
What's the safety risk?
Too few emergency exits, or exits in the wrong places, can slow passenger evacuation during an emergency and increase injury risk. There is no driver warning sign to watch for; this recall is about the bus emergency egress layout and added window parts. Confirm the VIN, then arrange the free egress window parts and instructions. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2012-2025 New Flyer Xcelsior is included in this recall.
- Contact New Flyer customer service to request the free emergency-egress-window parts and instructions.
- Use the mailed parts and instructions to add the emergency egress windows that fix the missing or incorrectly located exit issue.
- Reference recall number 25V542 when you call or schedule the repair work.
- Review passenger-service plans until the repair is complete; this recall involves emergency exits needed for passenger evacuation.
What happens at the repair
New Flyer will mail the instructions and parts needed to add emergency egress windows at no charge. A New Flyer service technician or approved service facility installs the added emergency exit windows so the bus has the required emergency exits in the correct locations. Parts and labor are covered under recall 25V542. New Flyer uses its standard reimbursement plan for this recall. If you already paid for this same emergency exit window work before the recall notice, keep your repair invoice and payment records and contact New Flyer customer service about reimbursement.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 22, 2025 | NHTSA published the recall |
|---|---|
| October 8, 2025 | Owner notification mailed |
| October 17, 2025 | Interim owner notification (was planned for this date) |
Frequently asked questions
What is recall 25V542?
Recall 25V542 covers 2,354 2012-2025 New Flyer Xcelsior buses built without enough emergency exits or with exits in the wrong location. New Flyer will provide instructions and parts to add emergency egress windows free of charge.
What should I do if my 2012-2025 New Flyer Xcelsior is on this recall?
Check your VIN to confirm whether your specific bus is included in recall 25V542. If it is, contact New Flyer customer service at 1-800-241-2947 and ask for the emergency-egress-window instructions and parts. The recall remedy is free.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to fix the defect at no cost, and New Flyer's remedy provides the instructions and necessary parts for additional emergency egress windows free of charge.
What is the safety risk?
The risk is delayed emergency exit from the bus. If the bus does not have enough emergency exits, or the exits are placed incorrectly, passengers can have a harder time getting out during an emergency, increasing injury risk.
When were owners notified about recall 25V542?
New Flyer mailed owner notification letters on October 8, 2025. If you operate or own a 2012-2025 Xcelsior bus and did not receive a letter, check your VIN and reference recall 25V542 when contacting New Flyer customer service.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V542000 |
|---|---|
| New Flyer customer service | 1-800-241-2947 |
| NHTSA recall # | 25V542 |
| NHTSA recall # (full) | 25V542000 |
Source documents
-
Download Quarterly Report (PDF) - Download Misc. Document (PDF)
- Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (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 →