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NHTSA campaign 25V631000

2019–2025 NEW Flyer XE35 and 2 other NEW Flyer models: electrical system recall

A short circuit in a high voltage battery increases the risk of a fire.

critical Park outside 655 vehicles affected 4% reported repaired

What was reported

Source: manufacturer filing, 49 CFR Part 573
Problem New Flyer of America, Inc. (New Flyer) is recalling certain 2019 XE35, 2021-2025 XE35, XE40, and XE60 transit buses. The high voltage battery may experience a short circuit within the battery module when charging to near or full capacity. Risk A short circuit in a high voltage battery increases the risk of a fire. Fix Owners are advised to park outside and away from structures until the recall repair is complete. Owners are also advised to avoid charging vehicles above 75% capacity. New Flyer will replace the batteries, free of charge. This is a Phased campaign. Phase 1 will include 35 buses. New Flyer notified owners on 3/24/2026. Phase 2 will include 100 buses. New Flyer notified owners on 6/25/2026. Phase 3 will include 120 buses. New Flyer will notified owners on 9/9/2026. Phase 4 will include 120 buses. New Flyer will notify owners on or about 12/14/2026. Phase 5 will include 120 buses. New Flyer will notify owners on or about 3/15/2027. Phase 6 will include 80 buses. New Flyer will notify owners on or about 6/14/2027. Phase 7 will include 80 buses. New Flyer will notify owners on or about 9/27/2027. Interim owner notification letters explaining the safety risk were mailed November 12, 2025. A second letter will be sent once the remedy is available. Owners may contact New Flyer's customer service at 1-800-241-2947.

Reported to NHTSA Sep 19, 2025 by New Flyer of America, Inc, owners notified Mar 24, 2026.

Which vehicles are covered

Source: NHTSA campaign 25V631000
Model yearOn WhichTrim
2019 NEW Flyer XE35
2021 NEW Flyer XE35
2022 NEW Flyer XE35
2023 NEW Flyer XE35
2024 NEW Flyer XE35
2025 NEW Flyer XE35
2021 NEW Flyer XE40
2022 NEW Flyer XE40
2023 NEW Flyer XE40
2024 NEW Flyer XE40
2025 NEW Flyer XE40
2021 NEW Flyer XE60
2022 NEW Flyer XE60
2023 NEW Flyer XE60
2024 NEW Flyer XE60
2025 NEW Flyer XE60

None of the vehicles this campaign names has a page on WhichTrim: the catalogue covers the cars, trucks and SUVs the EPA certifies from 2016 on, and these vehicles fall outside it — older model years, or motorhomes, trailers, buses, motorcycles and chassis cabs the EPA does not rate. The campaign record above is complete as filed, and whether one specific vehicle is included is settled by its VIN. Other campaigns on vehicles without a page here →

How much of it has been fixed

Source: manufacturer quarterly report, 49 CFR 573.7
Reported repaired 4%

of the campaign

2 quarters into the six-quarter reporting window, and still climbing.

This is the manufacturer's own cumulative count of vehicles it has inspected and repaired, divided by the vehicles the campaign covers. It files that count with NHTSA every quarter for six consecutive quarters, starting from the quarter in which owners were told a remedy was ready, and then the obligation ends — so a figure on an older campaign is where the count stopped, not where it stands today.

It rarely reaches 100%, and not because the work was not done. The same report asks manufacturers to count vehicles they could not reach at all — exported, stolen, scrapped, or simply never located — and those stay in the denominator. A low number means a lot of these vehicles are still out there unrepaired; it does not tell you which ones.

The federal paperwork

Source: nhtsa.gov

Filed documents

  • Defect report PDF — The manufacturer's own filing to NHTSA describing the defect, the risk and the affected build range.

Check one specific vehicle

A recall applies to a build range, so year, make and model cannot settle it. NHTSA checks a VIN against the manufacturer's own list and tells you whether the repair is still outstanding on that vehicle.

NHTSA VIN recall lookup →

Campaign 25V631000

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Common questions

Source: NHTSA, 49 CFR Part 573

What does this advisory mean?

Park outside means the vehicle can catch fire while parked and switched off, so it should be kept away from buildings and other vehicles until the repair is done. These are the two most serious things NHTSA can attach to a campaign, and both mean the risk exists while the vehicle is switched off.

Does this recall repair cost anything?

No. Federal law requires the manufacturer to remedy a safety defect or a compliance failure at no charge, for vehicles up to 15 years old measured from the date of first sale. A dealer that asks you to pay for a recall repair is in the wrong.

How do I know whether my vehicle is included?

By VIN, not by model year. The manufacturer files a build range with NHTSA and only vehicles inside it are covered, so two identical-looking cars from the same year can differ. NHTSA's own lookup checks a VIN against the manufacturer's list.

What if the repair is not available yet?

It happens, and often. Manufacturers must notify owners when a defect is found even if the parts or the software are not ready, then notify them a second time once the remedy exists. The remedy filed for this campaign is described above.

What did the manufacturer say was wrong?

The problem, risk and fix quoted on this page are the manufacturer's own words as filed with NHTSA under 49 CFR Part 573. WhichTrim does not paraphrase them.

Who started this recall?

NHTSA's record credits NHTSA's Office of Defects Investigation. A recall can begin with the manufacturer's own testing, with a defect investigation, or with a compliance test against a Federal Motor Vehicle Safety Standard.