Use cautionVehicle recall · NHTSA · Published August 29, 2025
New Flyer XE35 (2025) Recall: Battery Overheating Fire Risk
New Flyer recalls certain 2025 XE35 buses due to battery overheating that could cause fire. Owners will get free battery module replacements and BMS software updates.
“New Flyer XE35 (2025) Recall: Battery Overheating Fire Risk.” GovInfoNow, updated October 8, 2026. https://govinfonow.com/recall/1342308-new-flyer-xe35-2025-recall-battery-overheating-fire-risk. Based on NHTSA recall #25V566000 (https://www.nhtsa.gov/recalls?nhtsaId=25V566000).
New Flyer of America, Inc. recalled certain XE35 buses manufactured between 2019 and 2025 due to a battery module overheating hazard that increases the risk of fire, according to the National Highway Traffic Safety Administration (NHTSA) on August 29, 2025. Owners should contact New Flyer's customer service at 1-800-241-2947.
How to tell if you have it
New Flyer XE35, 2019-2025
New Flyer XE40, 2013, 2017-2025
New Flyer XE60, 2019-2025
New Flyer XHE40, 2023-2025
New Flyer XHE60, 2024-2025
What to do
New Flyer will inspect and replace the battery module as necessary. New Flyer will also update the BMS software. All repairs will be performed free of charge.
The hazard
An inadequate weld on the high voltage battery busbar and incorrect software may cause the battery module to overheat, increasing the risk of a fire.
Context
GovInfoNow's records show New Flyer of America, Inc. has 7 other recalls on record since 2018-12-06. Other recent recalls of similar products include New Flyer XE35 (2025) Recall: Unintended Acceleration Risk (2026-03-13), New Flyer XD60 (2017) Recall: ABS/ESC Warning Light Failure Risk (2025-12-19), and New Flyer XE35 (2025) Recall: Fire Risk from Battery Short Circuit (2025-09-20). Volkswagen ID.4 (2023-2025) Electrical System Recall: Fire Risk from Overheating Battery occurred on 2026-01-21, while Volvo EX30 (2025) recalls regarding high-voltage battery fire risk were issued on 2026-01-02 and 2026-02-20.
How to tell if you have this one
Check if your bus has a New Flyer XE35 model with a year between 2013 and 2025. The recall covers buses sold from 2013 through 2025.
Brand
New Flyer
Category
Vehicle
Based on the official NHTSA remedy
What to do — step by step
Contact New Flyer Customer Service
Call 1-800-241-2947 to schedule a free battery module inspection and replacement.
Get Software Update
New Flyer will update the battery management system software for free as part of the repair process.
Official remedy
What NHTSA says to do
New Flyer will inspect and replace the battery module as necessary. New Flyer will also update the BMS software. All repairs will be performed free of charge. Owner notification letters were mailed October 6, 2025. Owners may contact New Flyer's customer service at 1-800-241-2947.
How this recall unfolded
Recall timeline
Owners were mailed letters 38 days after NHTSA received the defect report.
1NHTSA received the defect report
2Owner letters mailed
3Added to GovInfoNow
Dates from the agency record only; steps without a date are left out.
The facts (hazard, remedy, dates, manufacturer) are pulled from the official NHTSA recall record. The plain-language summary and step-by-step checklist are written by GovInfoNow to make the official notice easier to act on — they don’t replace it.
Plain-language summary written by qwen3:4b on October 8, 2026, from the official record above. Not reviewed by a person — if it conflicts with the NHTSA notice, the notice is correct. Report an error on this page.
GovInfoNow is an independent service and is not a government agency. We republish official NHTSA recall data; we don’t issue, amend or administer recalls.