Approximately 680 New Flyer buses and “a small number” of MCI coaches which have already been delivered to customers are potentially at risk of developing a fault in their battery packs.

The new firm order for 97 45-foot ‘D45 CRT’ commuter coaches makes use of the additional options granted in the original contract.

The new 35,000-square-foot facility comprises twelve service bays and an outdoor wash station and provides body and paint services, refurbishment, fire restoration, and general repairs.

MCI’s engineering team has reportedly added more than 20 quality upgrades to the tri-axle coach, displayed at the United Motorcoach Association’s 2025 expo between 20-23 February.

The contract stipulates a firm order for eighty 45-foot ‘D45 CRT’ commuter coaches, with additional unspecified options.

The coaches will serve on Houston’s park-and-ride service routes, connecting the suburbs with the downtown area.

Parent company NFI has made “significant” investments in infrastructure and workforce at the site, including the installation of chargers, expansion of storage and commissioning areas, and retraining of staff, in order to prepare the facility for electric coach production.

The money is derived from the Canadian government’s Jobs and Growth Fund through Prairies Economic Development Canada, a federal department responsible for the provinces of Alberta, Manitoba, and Saskatchewan.

The two J4500 CHARGE coaches were handed over to an unnamed operator in the California Bay Area, where they will be used by commuters working in the tech industry.

The ‘D4020 ISTV’ (Inmate Security Transportation Vehicle) is the successor to the ‘D4000 ISTV’ and is based on the newest generation platform for the D series of commuter coaches.

The D45 CRT CHARGE is a battery-electric version of the high-floor D45 Commuter Rapid Transit series of coaches, providing a range of over 225 miles.

The J4500, a tri-axle 45-foot coach with a passenger capacity of 60, was introduced in 2001 - MCI claims it has been the industry’s best-selling model in North America since 2004.