Recall 25V631 covers 655 2019, 2021, 2022, 2023, 2024, 2025 New Flyer XE35, XE40, and XE60 buses for battery short circuits. Park outside, charge below 75%. Free battery replacement is phased.
A short circuit in the high voltage battery increases the risk of a fire. Park the bus outside and away from structures until the recall repair is complete, and avoid charging above 75 percent. If a temperature warning appears or smoke is visible, keep the bus parked and call New Flyer service. Repair will be free at any franchised New Flyer dealer once New Flyer opens it.
New Flyer is recalling 655 2019, 2021, 2022, 2023, 2024, 2025 XE35, XE60, and XE40 transit buses because the high voltage battery can short circuit while charging near or full capacity. That short circuit increases the risk of a fire, so owners should park outside and away from structures until New Flyer opens the final dealer repair, which will be free.
Does this recall apply to your specific vehicle?
The official, free per-VIN recall check is run by NHTSA. Enter your VIN and we'll forward you directly — and add you to a free watchlist so you hear about new recalls for your vehicle.
Check my VIN at NHTSARecallNotify doesn't check your VIN — NHTSA's official tool does. We use your email only to alert you to new recalls.
Watch this vehicle for recalls
Add it to your free watchlist and we will alert you as new federal recalls are posted for your year, make and model. New-recall alerts are rolling out now.
You are on the watchlist.
We will email you as new federal recalls are posted for your vehicle.
What's wrong?
The HV battery is the large high voltage battery pack that stores energy for the electric propulsion system. On 2019, 2021, 2022, 2023, 2024, 2025 New Flyer XE35, XE60, and XE40 buses in this recall, the pack uses Freudenberg Gen 3 HE battery modules. Those modules supply power to move the bus and are also charged when the bus is connected to charging equipment.
The problem is inside the battery cells. When the battery charges to near or full capacity, a cell fault or short circuit can develop within a module. New Flyer has not identified the precise cause of the short circuit. The defect is tied to buses equipped with the Freudenberg Gen 3 HE batteries, and the remedy parts will come from a different supplier.
If the bus is powered on, the driver display shows temperature warnings. If the bus is off, visible smoke from the affected battery is the warning sign to watch for.
Who's affected?
The included buses span the XE35, XE40, and XE60 models, all using the same high-voltage traction battery.
| 2022 New Flyer XE35 | high-voltage traction battery |
|---|---|
| 2019 New Flyer XE35 | high-voltage traction battery |
| 2021 New Flyer XE60 | high-voltage traction battery |
| 2022 New Flyer XE60 | high-voltage traction battery |
| 2025 New Flyer XE60 | high-voltage traction battery |
| 2025 New Flyer XE35 | high-voltage traction battery |
| 2021 New Flyer XE35 | high-voltage traction battery |
| 2025 New Flyer XE40 | high-voltage traction battery |
| 2021 New Flyer XE40 | high-voltage traction battery |
| 2023 New Flyer XE60 | high-voltage traction battery |
| 2024 New Flyer XE60 | high-voltage traction battery |
| 2023 New Flyer XE35 | high-voltage traction battery |
| 2024 New Flyer XE35 | high-voltage traction battery |
| 2024 New Flyer XE40 | high-voltage traction battery |
| 2022 New Flyer XE40 | high-voltage traction battery |
| 2023 New Flyer XE40 | high-voltage traction battery |
| Units affected | 655 |
| Field incidents | NHTSA has logged 8 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?
A short circuit in the high voltage battery increases the risk of a fire. Park the bus outside and away from structures until the recall repair is complete, and avoid charging above 75 percent. If a temperature warning appears or smoke is visible, keep the bus parked and call New Flyer service. Repair will be free at any franchised New Flyer dealer once New Flyer opens it.
What should I do?
- Check your VIN to confirm your 2019, 2021, 2022, 2023, 2024, 2025 New Flyer XE35, XE60, or XE40 bus is included in this recall.
- Wait for New Flyer's remedy notice before scheduling the free high-voltage battery replacement that addresses the charging-related short circuit and fire risk.
- Park the bus outside and away from structures until the battery replacement is complete.
- Limit charging to 75% or less until the repair is complete.
- Call New Flyer customer service at 1-800-241-2947 with questions and reference recall number 25V631 when you call.
What happens at the repair
Until the final repair opens for the affected phase, follow New Flyer's interim guidance: park outside, park away from structures, and do not charge the buses above 75% capacity. Once the repair is available for your phase, a New Flyer technician will replace the high voltage batteries free of charge. Parts and labor are covered under the recall. If you paid out of pocket for a related battery repair before the recall notice, New Flyer's standard reimbursement plan covers documented qualifying expenses. Contact New Flyer customer service or ask the service desk how to submit the paperwork.
| Reimbursement | Reimbursement available |
|---|
Timeline
| September 19, 2025 | NHTSA published the recall |
|---|---|
| November 14, 2025 | Dealer notification began |
| November 14, 2025 | Dealer notification ended |
| November 14, 2025 | Interim owner notification (was planned for this date) |
| March 24, 2026 | Owner notification mailed |
Frequently asked questions
What is recall 25V631?
Recall 25V631 covers 655 New Flyer XE35, XE60, and XE40 transit buses with high voltage batteries that can short circuit while charging near full capacity. A battery short circuit increases fire risk. New Flyer will replace the batteries for free through a phased repair campaign.
What should I do if my 2019, 2021, 2022, 2023, 2024, 2025 New Flyer XE35, XE60, or XE40 is on this recall?
Check your VIN to confirm your specific bus is included in recall 25V631. If it is, park outside and away from structures, avoid charging above 75% capacity, and contact New Flyer customer service at 1-800-241-2947 for phase timing and repair instructions.
Is the recall repair free?
Yes. Federal recall law requires the manufacturer to repair the defect at no cost, and New Flyer will replace the affected batteries free of charge. Because this is a phased campaign, the free repair opens by assigned phase instead of all buses at once.
What is the safety risk?
The safety risk is fire. The high voltage battery can develop a short circuit while charging near or at full capacity. Until the recall repair is complete, keep the bus parked outside and away from structures, and avoid charging it above 75% capacity.
When will New Flyer notify owners about the repair?
New Flyer mailed interim owner letters on November 12, 2025. Phase 1 owner notices were mailed on March 24, 2026. Later phase notices are scheduled by group, with New Flyer sending instructions when each assigned repair phase opens.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/25V631000 |
|---|---|
| New Flyer customer service | 1-800-241-2947 |
| NHTSA recall # | 25V631 |
| NHTSA recall # (full) | 25V631000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Investigation Document (PDF) (PDF)
- Download Owner Notification Letter (PDF)
- Download Recall Document (PDF) (PDF)
- Download Remedy Instructions (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 20, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →