New Flyer of America, Inc. is recalling 6,673 transit buses because a software flaw prevents ABS and Electronic Stability Control (ESC) warning lamps from illuminating during system failures. These vehicles fail to comply with federal safety standards governing air brakes and electronic stability control systems. A non-functioning warning lamp increases crash risks by failing to alert drivers of critical braking system outages.
Highlights
- The recall affects 6,673 units spanning model years 2013 through 2026.
- Impacted models include XD, XDE, XE, XHE, XN, and XT variants in multiple lengths.
- WABCO-manufactured ABS/ESC modules lose communication without triggering a dash warning.
- New Flyer will provide a free software update to introduce a “heartbeat” signal for module monitoring.
Validation and Technical Cause
New Flyer Quality teams first identified the issue in September 2025 during production when a disconnected module failed to trigger a warning. Engineering analysis confirmed that vehicles utilizing J1939 communications solely for ABS lamp function—rather than traditional hard-wiring—lacked a “heartbeat” signal to detect outages. Without this signal, the system cannot verify the module is operational, leaving the driver unaware of a potential braking system failure.
Safety Compliance and Risks
The defect violates FMVSS 121 (Air brake systems) and FMVSS 136 (Electronic Stability Control Systems on Heavy Vehicles). Drivers may also notice that the ABS lamp does not illuminate momentarily during the standard start-up sequence, which is a key indicator of proper communication. A failure in these systems without a visual alert significantly increases the risk of a crash.
Affected Componentry
The recall involves five specific WABCO ABS/ESC module part numbers used as Tier 1 components. These modules are integrated across a wide range of fuel types, including Hybrid Electric, Compressed Natural Gas (CNG), Fuel Cell, and Electric Battery Power:
- 504269 (ABS-ECU E BASIC 24V J1939)
- 642879 (ABS-ECU E UNIVERSAL 24V J1939)
- 642884 (ABS-ECU E BASIC 24V J1939)
- 1099541 (ABS-ECU 24V J1939 500k BAUD)
- 1156861 (ABS-ECU 24V J1939 500k BAUD)
Remedy and Timeline
New Flyer will release updated software that establishes a constant “heartbeat” signal between the dash and the module. Should communication fail, the ABS lamp will illuminate and remain steady while the ignition is on. Owner notification letters are scheduled for distribution on February 13, 2026.
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