AI Damage2021 NEW Flyer XDE40: common problems
The maker issued 10 service bulletins for this year. Details by component below, with sources.
Key figures
- Technical service bulletins (TSB)
- 10
Components owners complain about
| Component | Owner complaints | involving a crash | Technical service bulletins (TSB) |
|---|---|---|---|
| Electrical system | 0 | 0 | 4 |
| Fuel/propulsion system | 0 | 0 | 3 |
| Engine | 0 | 0 | 2 |
| Equipment | 0 | 0 | 1 |
| Powertrain | 0 | 0 | 1 |
| Seats | 0 | 0 | 1 |
| Steering | 0 | 0 | 1 |
| Structure | 0 | 0 | 1 |
| Suspension | 0 | 0 | 1 |
Comparison
What to check before buying
- Electrical system. Scan all modules, test the battery and alternator, inspect connectors near the impact zone.
- Fuel/propulsion system. Fuel smell, leaks, rough running, fuel-system codes.
- Engine. Cold start, unusual noises, oil leaks and engine codes.
- Powertrain. Shift quality under load, harsh shifts, transmission codes, CV joints.
Manufacturer service bulletins
Bulletin titles as filed with NHTSA.
- Instructions to modify ECP & MCP pump connectors to prevent water intrusion
- Instructions to Service to remove bypassed engine calibration from ECM and replace DEF sensor as required
- Instruction to Service to check the four mounting bolts that attach the steering box mounting bracket to…
Instruction to Service to check the four mounting bolts that attach the steering box mounting bracket to the frame of the bus to ensure they are torqued to the correct value.
- Instructions to Service to incorporate a PLC Update to prevent interlock activation when CAN speed…
- Instruction to Service for updating the battery program on certain ELFA2 buses for Improved BMS response…
Instruction to Service for updating the battery program on certain ELFA2 buses for Improved BMS response to overcharging and other functional safety mechanisms, more robust detection of failure modes through DTCs…
- Instruction to Service 60838 to check/replace fuse box mounting hardware as required
- Technical Instruction describing how to rework and adjust the stop request pull cord cover
- Technical Instruction describing how to reseal floor seam trims
- Technical Instruction describing how to tighten hardware and replace rivets on upper deck cantilever seats…
- This technical instruction describes how to replace dust covers and seal and protect the harnesses…
This technical instruction describes how to replace dust covers and seal and protect the harnesses associated with the Smart Rider suspension leveling system for 40 foot buses with components installed on both axles.
Other years of this model
Questions and answers
What are the most common problems with the 2021 NEW Flyer XDE40?
There are no owner complaints in the NHTSA data for this year; the data comes from 10 manufacturer service bulletins.
How many service bulletins (TSB) were issued for the 2021 NEW Flyer XDE40?
NHTSA lists 10 manufacturer service bulletins for this year. A bulletin tells dealers how to diagnose or fix a known issue; it is not a recall.
Should I buy a 2021 NEW Flyer XDE40 from a US auction?
Owner complaints describe defects, not crash damage. Before bidding, check the components listed above and review the lot photos: VinWind builds a report of visible and hidden damage by VIN.
Other 2021 models
Read also
Sources: public NHTSA data (USA): service bulletins and owner complaints; YouTube: links to videos credited to their authors. Complaints are owner statements not verified by NHTSA, and describe defects rather than crash damage. Data updated 2026-11-04.