Recall Register

2021 New Flyer XD40: recalls and complaints

NHTSA lists 6 recall campaigns for the 2021 New Flyer XD40. The newest campaign is 25V898000. NHTSA received the report on 19 Dec 2025. The NHTSA record gives the component Service Brakes, Air / Antilock. NHTSA has no complaint on file for this model year.

The NHTSA recall file shows no do-not-drive advisory and no park-outside advisory on these campaigns.

This page cannot show if a recall applies to one vehicle. The NHTSA VIN lookup shows the unrepaired recalls of one vehicle.

Remedy of the newest campaign, 25V898000, in the NHTSA record

New Flyer will update the software, free of charge. Owner notification letters were mailed February 17, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.
NHTSA VIN lookup

Complaint information entered into NHTSA’s Office of Defects Investigation vehicle owner's complaint database is used with other data sources to identify safety issues that warrant investigation and to determine if a safety-related defect trend exists.

NHTSA publishes these words. Source: NHTSA Datasets and APIs, section Complaints, read on . Complaint file through . Recall file through .

Since the last update

No tracked figure of this page changed in a data update. What the log tracks

All updates to the register

Recall campaigns

6 campaigns, newest first. 12,737 units in total.

  • 25V898000Service Brakes, Air / Antilock
  • 23V722000Power Train / Driveline / Driveshaft
  • 22V637000Steering
  • 21V576000Fuel System, Diesel / Delivery / Hoses, Lines/Piping, and Fittings
  • 21V532000Engine and Engine Cooling / Exhaust System / Manifold/Header/Muffler/Tail Pipe
  • 21V365000Fuel System, Diesel / Fuel Injection System / Fuel Rail

  1. 25V898000Received . 6,673 units.

    Service Brakes, Air / Antilock

    Defect, in the NHTSA record
    New Flyer of America, Inc. (New Flyer) is recalling certain XD35, XDE35, XE35, XN35, XD40, XDE40, XE40, XHE40, XN40, XT40, XD60, XDE60, XE60, XN60, XT60, and XHE60 transit buses. Please refer to New Flyer's recall report for specific model year information. The antilock braking (ABS) and electronic stability control (ESC) module may lose communication and fail without illuminating the warning lights. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard numbers 121, "Air Brake Systems" and 136, "Electronic Stability Control Systems on Heavy Vehicles."
    Consequence, in the NHTSA record
    An ABS or ESC warning light that fails to illuminate will not alert the driver to the loss of ABS or ESC, increasing the risk of a crash.
    Remedy, in the NHTSA record
    New Flyer will update the software, free of charge. Owner notification letters were mailed February 17, 2026. Owners may contact New Flyer's customer service at 1-800-241-2947.

    Report filed by New Flyer of America, Inc.. Owner notification date in the NHTSA record: .

  2. 23V722000Received . 2,351 units.

    Power Train / Driveline / Driveshaft

    Defect, in the NHTSA record
    New Flyer of America, Inc. (New Flyer) is recalling certain 2019-2024 XD35, XD40, XN35, and XN40 transit buses. The transmission yoke may separate, resulting in driveshaft separation and a sudden loss of drive power.
    Consequence, in the NHTSA record
    A sudden loss of drive power can increase the risk of a crash.
    Remedy, in the NHTSA record
    New Flyer will work with the equipment manufacturer, Allison Transmission Inc., to inspect, and if necessary, tighten loose transmission yoke bolts, free of charge. Owner notification letters were mailed December 9, 2023. Owners may contact New Flyer customer service at 1-800-241-2947. New Flyer's number for this recall is R23-20.

    Report filed by New Flyer of America, Inc.. Manufacturer campaign number R23-20. Owner notification date in the NHTSA record: .

  3. 22V637000Received . 55 units.

    Steering

    Defect, in the NHTSA record
    New Flyer of America, Inc. (New Flyer) is recalling certain 2021-2022 XD40, XD60, XDE40, 2022 XN35, XE40, XN40, and 2021 XN60 transit buses. The steering gears may have been incorrectly assembled, which can cause the gear to fracture.
    Consequence, in the NHTSA record
    A fractured steering gear can cause a loss of steering control, increasing the risk of a crash.
    Remedy, in the NHTSA record
    Dealers will inspect and replace the steering gear if required, free of charge. Owner notification letters were mailed on September 2, 2022. Owners may contact New Flyer's customer service at 1-204-224-6706. New Flyer's number for this recall is R22-026.

    Report filed by New Flyer of America, Inc.. Manufacturer campaign number R22-026. Owner notification date in the NHTSA record: .

  4. 21V576000Received . 30 units.

    Fuel System, Diesel / Delivery / Hoses, Lines/Piping, and Fittings

    Defect, in the NHTSA record
    New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD40 and XD35 vehicles equipped with Cummins L9 Diesel engines that have remote Stage 2 fuel filters and pressurized hoses. A fuel leak may occur from the fuel hose between the fuel pump and the remote fuel filter head.
    Consequence, in the NHTSA record
    A fuel leak in the presence of an ignition source increases the risk of a fire.
    Remedy, in the NHTSA record
    Cummins will replace the fuel hoses, free of charge. Owner notification letters were mailed on August 3, 2021. Owners may contact New Flyer's customer service at 1-204-224-6706.

    Report filed by New Flyer of America, Inc.. Owner notification date in the NHTSA record: .

  5. 21V532000Received . 28 units.

    Engine and Engine Cooling / Exhaust System / Manifold/Header/Muffler/Tail Pipe

    Defect, in the NHTSA record
    New Flyer of America, Inc. (New Flyer) is recalling certain 2021 XD35 and XD40 vehicles equipped with 2021 Model Year Cummins L9 Diesel Engines. The engine calibration software's management of the injection of Diesel Exhaust Fluid can allow excessive ammonia to be emitted from tailpipe exhaust.
    Consequence, in the NHTSA record
    Exposure to high levels of ammonia can increase the risk of injury.
    Remedy, in the NHTSA record
    Cummins will recalibrate the engine, free of charge. Owner notification letters were mailed on July 23, 2021. Owners may contact New Flyer's customer service at 1-800-204-224-6706. New Flyer's number for this recall is R21-013.

    Report filed by New Flyer of America, Inc.. Manufacturer campaign number R21-013. Owner notification date in the NHTSA record: .

  6. 21V365000Received . 3,600 units.

    Fuel System, Diesel / Fuel Injection System / Fuel Rail

    Defect, in the NHTSA record
    New Flyer of America, Inc. (New Flyer) is recalling certain 2017-2021 XD40, XD35, 2016-2021 XD60, 2017 XDE35, 2016-2020 XDE40, XDE60 vehicles. The sealing washer may not seat correctly in the pilot bore holes, allowing the high pressure fuel rail assembly to leak.
    Consequence, in the NHTSA record
    A fuel leak in the presence of an ignition source increases the risk of a fire.
    Remedy, in the NHTSA record
    New Flyer will inspect the rail threads, and replace the rail as necessary, free of charge. Owner notification letters were mailed on June 28, 2021. Owners may contact New Flyer customer service at 1-204-224-6706. New Flyer's number for this recall is R21-008.

    Report filed by New Flyer of America, Inc.. Manufacturer campaign number R21-008. Owner notification date in the NHTSA record: .

The campaign number opens the NHTSA record. Each quotation is the text of the NHTSA recall file.

Recall campaign: One recall in the NHTSA recall file, with one campaign number. A campaign can name many makes, models and model years.

Units: The number of vehicles or products that a recall can include. The manufacturer or the firm reports the number to the agency.

Complaints by component

The NHTSA complaint file has no complaint for this model year.

Investigations

The NHTSA investigation file has no investigation that names this model year.

Investigation: A study of a possible safety defect by the NHTSA Office of Defects Investigation. An investigation with no closing date in the NHTSA file is open.

Other model years

The number under each year is the number of recall campaigns.

  1. 20101
  2. 20112
  3. 20122
  4. 20133
  5. 20144
  6. 20155
  7. 20163
  8. 20175
  9. 20183
  10. 20193
  11. 20203
  12. 20216
  13. 20225
  14. 20235
  15. 20243
  16. 20251
  17. 20261

A year without a link has fewer than 2 campaigns and fewer than 25 complaints. It has no page.

Official channels

Cite this page

Recall Register. 2021 New Flyer XD40: recalls and complaints. https://recallregister.com/vehicle/new-flyer/xd40/2021/. Source: NHTSA Office of Defects Investigation, recall, complaint and investigation files. Data through .

Sources

Source
NHTSA Office of Defects Investigation
Licence
US government work, public domain
Recall file through
29 Sep 2026
Complaint file through
29 Mar 2018
First complaint in the file
1 Jan 1995
Manufacturer in the recall file
New Flyer of America, Inc.

The NHTSA record is the authority. A complaint count is the number of different complaint numbers for the make, the model and the model year. How the register is made. Report an error.

Questions

How many units are in the recall campaigns for the 2021 New Flyer XD40?
12,737 units in 6 campaigns. A campaign can name other models and model years, and its units include them.
How many recall campaigns does the New Flyer XD40 have for all model years?
NHTSA lists 23 recall campaigns for the New Flyer XD40, model years 2010 to 2026. 6 of them name the 2021 model year.
Is an NHTSA investigation of the 2021 New Flyer XD40 open?
The NHTSA investigation file has no investigation that names this model year.