New Flyer XD60 problems & complaints
What New Flyer XD60 owners have reported to NHTSA, the service bulletins the manufacturer sent dealers, and any federal defect investigations, by model year. See New Flyer XD60 safety recalls or check your VIN.
- Owner complaints
- 2
- Service bulletins (TSBs)
- 34+
- Crashes / fires reported
- 1 / 1
- Defect investigations
- 0
Complaints by model year
Complaints owners filed with NHTSA, by the model year of the vehicle. A high count can also mean a popular year, so compare it with how many were sold.
| Year | Complaints | Crashes | Fires | Injured | Deaths | TSBs |
|---|---|---|---|---|---|---|
| 2026 | 0 | 0 | 0 | 0 | 0 | 2 |
| 2025 | 0 | 0 | 0 | 0 | 0 | 3 |
| 2024 | 0 | 0 | 0 | 0 | 0 | 5 |
| 2023 | 0 | 0 | 0 | 0 | 0 | 3 |
| 2022 | 0 | 0 | 0 | 0 | 0 | 4 |
| 2021 | 0 | 0 | 0 | 0 | 0 | 8 |
| 2020 | 0 | 0 | 0 | 0 | 0 | 15 |
| 2019 | 0 | 0 | 0 | 0 | 0 | 13 |
| 2018 | 0 | 0 | 0 | 0 | 0 | 6 |
| 2017 | 1 | 1 | 0 | 0 | 0 | 19 |
| 2016 | 0 | 0 | 0 | 0 | 0 | 25 |
| 2015 | 0 | 0 | 0 | 0 | 0 | 34 |
| 2014 | 0 | 0 | 0 | 0 | 0 | 20 |
| 2013 | 1 | 0 | 1 | 0 | 0 | 26 |
| 2012 | 0 | 0 | 0 | 0 | 0 | 19 |
Most reported problems
The vehicle systems named most often in New Flyer XD60 complaints (one complaint can name several).
Latest owner complaints
In the owners’ own words, as filed with NHTSA. Unverified reports; NHTSA removes personal details before publishing.
TL* THE CONTACT DROVE A 2017 NEW FLYER XD60. WHILE DRIVING APPROXIMATELY 5 MPH, THE REAR DRIVER'S SIDE RADIATOR DOOR PANEL DETACHED. AS A RESULT, THE DOOR PANEL STRUCK THE WINDSHIELD OF AN ONCOMING VEHICLE. THE CONTACT WAS ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD. THERE WERE NO INJURIES. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO A GARAGE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC TO DETERMINE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND STATED THAT THEY WERE MAKING IMPROVEMENTS TO THE DOOR LATCHES ON NEWER MODEL VEHICLES. THE APPROXIMATE FAILURE MILEAGE WAS 6,000. THE VIN WAS NOT AVAILABLE.
"U" BOLT THAT SECURES THE CHARGE AIR COOLER PIPE FOR THE ENGINE, RUBBED THROUGH THE 24 VOLTS DC POSITIVE CABLE INSULATION THAT CAUSE A DIRECT SHORT TO GROUND, IGNITING THE REAR ENGINE COMPARTMENT INTO FLAMES, WHILE THE BUS WAS PARKED BY THE FUEL ISLAND AFTER COMING OFF REVENUE SERVICE.
Technical service bulletins (TSBs)
Repair instructions and other communications the manufacturer sent dealers about known issues. A TSB is not a recall, and the repair is usually free only while the car is under warranty; ask your dealer for the bulletin number.
- ITS61870
Instructions provided to remove the existing brass/plastic swivel fitting and replacing with a more reliable solid brass fixed position fitting.
- ITS61748
Instructions for verifying/correcting torque on front destination sign mounting hardware installed on certain buses.
- ITS61086
Instructions to remove DEF sensor bypass calibration from engine ECM and new sensor installation AR - 12inch DEF tank
- ITS61080
Instructions to remove DEF sensor bypass calibration from engine ECM and new sensor installation AR - 18inch DEF tank CA emissions
- ITS61267
Instructions to replace current k-member with an upgraded casting design.
- TSIB 25-01
Thermo-King has issued a Service Bulletin (SB866-1) related to the clutch bearing maintenance on their QS616 HVAC screw compressor. New Flyer is issuing this Technical Service Information Bulletin to notify New Flyer XD60, XN60 and XDE60 bus operators about this Thermo-King Service Bulletin.
- ITS61038
Instructions to replace the A/C belt sheave (pulley) with an improved version to mitigate the AC belt splitting.
- ITS61063
Instructions to Service to remove bypassed engine calibration from ECM and replace DEF sensor as required.
- ITS61187
Instructions to Service to incorporate a PLC Update to prevent interlock activation when CAN speed messages are absent.
- ITS61015
Instruction to Service for inspection and correction of side console illumination lamps.
- ITS60969
Instruction to Service for proper correction of lower radius rod mounting hole location if found incorrect per ITS60966.
- ITS60966
Instruction to Service for proper inspection/verification of lower radius rod mounting hole location.
Source: NHTSA Office of Defects Investigation public data (complaints, manufacturer communications, investigations), model years 2010 and later. Had a safety problem? Report it to NHTSA.
Questions
What are the most common New Flyer XD60 problems?
In complaints filed with NHTSA for model years 2012–2026, owners most often name: engine, electrical system, latches/locks/linkages. 2 complaints are on record.
Is a complaint or a TSB the same as a recall?
No. A complaint is an unverified report from an owner. A technical service bulletin (TSB) is the manufacturer telling dealers how to fix a known issue; it is not a safety recall and is usually covered only under warranty. A recall is a formal safety action, and its repair is free.
How do I report a problem with my New Flyer XD60?
File a vehicle safety complaint at NHTSA.gov. NHTSA reads every report, and patterns of complaints are what open defect investigations and, eventually, recalls.