Recall 25V566 affects 1,170 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025 New Flyer buses for battery module overheating. Repair is free at any franchised New Flyer dealer.
New Flyer is recalling 1,170 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, 2025 XE35, XE40, XE60, XHE40, and XHE60 buses because an inadequate high-voltage battery busbar weld and incorrect software can let a battery module overheat. An overheated module increases the risk of a fire, and New Flyer dealers will complete the recall repair free of charge.
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What's wrong?
The high voltage module is part of the bus traction battery. It stores propulsion energy and feeds power through metal conductors inside the pack. A battery control system watches voltage and temperature, while contactors act like heavy electrical switches that open or close current flow.
On affected New Flyer buses, an incomplete J-bar weld inside the module can separate as the bus stays in service. That loose or high resistance connection can create localized arcing and heat at the weld. The original software does not stop current flow through the pack when that condition is detected, so heat can damage a nearby cell and lead to thermal runaway.
The warning sign is the diagnostic message "_XP:1_High Voltage Line Open / Fuse Blown String X." Operators also need to treat smoke from a roof-mounted energy storage pack as a serious battery warning.
Who's affected?
Covers five New Flyer bus models across non-consecutive model years, all tied to the high-voltage traction battery.
| 2023 New Flyer XE35 | high-voltage traction battery |
|---|---|
| 2023 New Flyer XHE40 | high-voltage traction battery |
| 2023 New Flyer XHE40 | high-voltage traction battery |
| 2025 New Flyer XHE40 | high-voltage traction battery |
| 2025 New Flyer XHE40 | high-voltage traction battery |
| 2013 New Flyer XE40 | high-voltage traction battery |
| 2013 New Flyer XE40 | high-voltage traction battery |
| 2023 New Flyer XE35 | high-voltage traction battery |
| 2024 New Flyer XE60 | high-voltage traction battery |
| 2024 New Flyer XE60 | high-voltage traction battery |
| 2025 New Flyer XHE60 | high-voltage traction battery |
| 2025 New Flyer XHE60 | high-voltage traction battery |
| 2025 New Flyer XE60 | high-voltage traction battery |
| 2025 New Flyer XE60 | high-voltage traction battery |
| 2017 New Flyer XE40 | high-voltage traction battery |
| 2017 New Flyer XE40 | high-voltage traction battery |
| 2018 New Flyer XE40 | high-voltage traction battery |
| 2018 New Flyer XE40 | high-voltage traction battery |
| 2024 New Flyer XE40 | high-voltage traction battery |
| 2024 New Flyer XE40 | high-voltage traction battery |
| 2025 New Flyer XE40 | high-voltage traction battery |
| 2025 New Flyer XE40 | high-voltage traction battery |
| 2024 New Flyer XE35 | high-voltage traction battery |
| 2024 New Flyer XE35 | high-voltage traction battery |
| 2024 New Flyer XHE60 | high-voltage traction battery |
| 2024 New Flyer XHE60 | high-voltage traction battery |
| 2019 New Flyer XE60 | high-voltage traction battery |
| 2019 New Flyer XE60 | high-voltage traction battery |
| 2020 New Flyer XE60 | high-voltage traction battery |
| 2020 New Flyer XE60 | high-voltage traction battery |
| 2021 New Flyer XE60 | high-voltage traction battery |
| 2021 New Flyer XE60 | high-voltage traction battery |
| 2022 New Flyer XE60 | high-voltage traction battery |
| 2022 New Flyer XE60 | high-voltage traction battery |
| 2023 New Flyer XE60 | high-voltage traction battery |
| 2023 New Flyer XE60 | high-voltage traction battery |
| 2019 New Flyer XE40 | high-voltage traction battery |
| 2019 New Flyer XE40 | high-voltage traction battery |
| 2020 New Flyer XE40 | high-voltage traction battery |
| 2020 New Flyer XE40 | high-voltage traction battery |
| 2021 New Flyer XE40 | high-voltage traction battery |
| 2021 New Flyer XE40 | high-voltage traction battery |
| 2022 New Flyer XE40 | high-voltage traction battery |
| 2022 New Flyer XE40 | high-voltage traction battery |
| 2023 New Flyer XE40 | high-voltage traction battery |
| 2023 New Flyer XE40 | high-voltage traction battery |
| 2025 New Flyer XE35 | high-voltage traction battery |
| 2025 New Flyer XE35 | high-voltage traction battery |
| 2024 New Flyer XHE40 | high-voltage traction battery |
| 2024 New Flyer XHE40 | high-voltage traction battery |
| 2019 New Flyer XE35 | high-voltage traction battery |
| 2019 New Flyer XE35 | high-voltage traction battery |
| 2020 New Flyer XE35 | high-voltage traction battery |
| 2020 New Flyer XE35 | high-voltage traction battery |
| 2021 New Flyer XE35 | high-voltage traction battery |
| 2021 New Flyer XE35 | high-voltage traction battery |
| 2022 New Flyer XE35 | high-voltage traction battery |
| 2022 New Flyer XE35 | high-voltage traction battery |
| Units affected | 1,170 |
| Field incidents | NHTSA has logged 2 field incidents to date. |
A matching year and New Flyer model does not confirm inclusion. Check your VIN to confirm whether your specific bus is included.
What's the safety risk?
A battery module that overheats increases the risk of a fire. If the bus shows the high-voltage line open or fuse blown warning, arrange service promptly before returning it to route use. New Flyer will inspect the module, replace it as necessary, and update BMS software. Repair is free at any franchised New Flyer dealer.
What should I do?
- Check your VIN to confirm your 2013, 2017, 2018, 2019, 2020, 2021, 2022, 2023, 2024, or 2025 New Flyer XE35, XHE40, XE40, XE60, or XHE60 bus is included in this recall.
- Contact a franchised New Flyer dealer to schedule the free battery-module inspection, battery replacement if needed, and BMS software update that address the overheating fire risk.
- Bring the owner letter if New Flyer mailed one. If not, reference recall number 25V566 when you call.
- Call New Flyer customer service at 1-800-241-2947 with questions about service timing or bus operating guidance before the repair.
- Confirm the dealer completed the battery-module work and BMS software update before returning the bus to normal service.
What happens at the repair
At the dealer, a New Flyer technician inspects the high voltage battery module and replaces it if the inspection shows it is needed. The technician also updates the BMS software so the battery management system uses the corrected programming. Parts and labor are free under the recall. New Flyer used its general reimbursement plan on file, so documented out-of-pocket repairs tied to this defect can be submitted for review. Bring your repair paperwork to the service desk.
| Reimbursement | Reimbursement available |
|---|
Timeline
| August 29, 2025 | NHTSA published the recall |
|---|---|
| October 6, 2025 | Owner notification mailed |
| October 17, 2025 | Dealer notification began |
| October 17, 2025 | Dealer notification ended |
Frequently asked questions
What is recall 25V566?
Recall 25V566 covers 1,170 New Flyer XE35, XE40, XE60, XHE40, and XHE60 buses with a high voltage battery busbar weld and BMS software issue. The defect can let a battery module overheat, increasing fire risk. New Flyer will inspect the battery module, replace it as needed, and update the BMS software for free.
What should I do if my 2013, 2017-2025 New Flyer XE35, XE40, XE60, XHE40, or XHE60 bus is on this recall?
Check your VIN to confirm the specific bus is included in recall 25V566. If it is, contact a franchised New Flyer service location or New Flyer customer service at 1-800-241-2947 to arrange the inspection, any needed battery module replacement, and the BMS software update.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and New Flyer states that all repairs for this recall will be performed free of charge. The free remedy includes the inspection, any necessary battery module replacement, and the BMS software update.
What is the safety risk?
The safety risk is battery module overheating and fire. NHTSA campaign 25V566 ties the risk to an inadequate weld on the high voltage battery busbar and incorrect BMS software. If your VIN is included, arrange the free New Flyer repair before returning the bus to normal service.
When were owners notified?
New Flyer mailed owner notification letters on October 6, 2025. If you operate one of the listed buses and did not receive a letter, check your VIN and reference recall 25V566 when contacting New Flyer customer service or your service provider.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V566000 |
|---|---|
| New Flyer customer service | 1-800-241-2947 |
| NHTSA recall # | 25V566 |
| NHTSA recall # (full) | 25V566000 |
Source documents
-
Download Quarterly Report (PDF) - Download Misc. Document (PDF)
- Download Remedy Instructions (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 →