36 of the
948 complaints filed about the Volvo XC60
are about the body and structure —
4% of everything owners reported.
The worst model year for it is 2010.
The vehicle's Supplemental Restraint System (SRS) safety network experienced a total electrical blackout, resulting in complete airbag non-deployment during a severe unibody-deforming hit-and-run collision. The vehicle was stationary when a high-speed car rammed the passenger side and front profile. Kinetic forces split the cast aluminum steering rack housing completely in half, fractured front CV axle joint cages, and shifted the engine subframe mounts (creating physical gaps and shiny mechanical abrasions beneath the rust layer). Despite catastrophic structural distortion—which twisted the greenhouse safety cage and cracked the windshield directly beneath the laser cluster—zero front, side, or curtain airbags deployed. No dashboard SRS warning lights illuminated prior to or after the crash.A post-crash scan by a Master Mechanic confirms high-speed CAN-bus fragmentation, storing module timeouts U016700, U042268, and steering column resistance deployment inhibitors B1C0224, B1CO424, B1C0524. Additional codes include P134600, P134613, P261086, P0A0F68, C006468, B109B15, B116415, and B108467.Teardown reveals extensive, pre-existing saltwater intrusion residue inside passenger footwell fuse blocks (Centers B/C) and the under-hood relay box, plus green cupric carbonate oxidation on chassis grounds. This induced extreme electrical resistance, blinding the SRS module's ability to read the crash pulse. Occupant safety was heavily compromised; the driver sustained a severe concussion, whiplash, and active neurological time-loss blackouts after being struck by flying cabin cargo during the pulse. Both front seatbelt receiver buckles permanently bound and locked. The vehicle was inspected by local police under an active criminal hit-and-run report. Diagnostic logs are preserved and available for federal review.
NHTSA complaint #11755236 — an unverified report by a vehicle owner.
Volvo 2025 XC60 T8. Rear liftgate closed without request nearly causing an eye injury. The liftgate was open, I was moving back and forth emptying packages from the cargo area. I turned to return to the car and the liftgate had started to come down (unrequested. I had NOT pushed the physical button on the liftgate or on the key fob). My eye was within 2 in of hitting the corner of the liftgate. I am taking the car to the dealer to report the incident. I do not see any active recalls posted for this safety issue.
NHTSA complaint #11752788 — an unverified report by a vehicle owner.
The seal on my 2020 Volvo XC60 moonroof allowed water to leak under the floorboards. My car is only 6 years old. We had a lot of rain over a short period and I noticed the sound of water sloshing around under the floor. Nothing was wet inside the car. My Check Engine light came on as well. I took it to the Volvo service dept. They are now saying wires are corroded and that it will cost me over $11,000 to fix this problem. Again - my car is only 6 years old, and less than 70K miles. With my previous Volvo, that I had for 18 years, I never had this problem.
NHTSA complaint #11742884 — an unverified report by a vehicle owner.
STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS
On December 28 the tailgate on my Volvo 2025 xc60 PHEV began to open and close randomly while it was not running, parked in my garage and and plugged in. I unplugged the car from the charger, firmly closed the tailgate and went back in side my house. I checked on the car several minutes later to find the tail gate open again. I again firmly closed the tail gate and this time ensured that I locked the car with the button on the key fob. 10 minutes later the tailgate was open again, while the car was parked, turned off and not plugged in. After closing the tailgate again, I now locked the car via the app. When I checked again in 15 minutes the car was unlocked, but the tailgate was still closed. All of these incidents happened between 8 am and 9:45am. I was able to take video and still pictures of the incidents. Several weeks ago, I was driving and noticed that my tailgate was open. I had recently left a shopping center so I figured I had some how not closed the tailgate properly. This would be the first time I ever made such a mistake. I pulled over, closed the tailgate and continued on. I now wonder if this was a similar problem. Safety risks include injury to people from the tailgate itself and risk of loss and damage to items in the vehicle and the vehicle itself. This is an additional incident of a previously reported issue with the electrical system of this vehicle.
NHTSA complaint #11707321 — an unverified report by a vehicle owner.
The rear tailgate has a feature that allows a driver to open it by waving their foot underneath the bumper in case their hands are full. The system will also unsafely cause the door to close if a person places their foot too close when loading cargo. This has twice lowered the door on my head. The most recent time causing bleeding when the latch struck my scalp. This feature should only be used to open the gate, not close it.
NHTSA complaint #11701020 — an unverified report by a vehicle owner.
Factory installed windshield is leaking profusely due to faulty adhesive/primer. This is a well known issue that causes havoc on vital electronic systems and should be a national recall. The loose windshield bond can cause the windshield to detach during a crash. The failed windshield bond compromises the structural integrity of the roof.
NHTSA complaint #11667548 — an unverified report by a vehicle owner.
After it rains, i've noticed water collecting in both the passenger and driver side footbeds. It started off nominally and I was easily able to use a cloth. I thought it might have been human error, that I left the window cracked open a bit. The most recent incident (this past weekend 5/4/24) there was a significant puddle on the driver's side. After further research, I discovered the culprit is likely an unbonded windshield, and that this is a KNOWN issue for Volvos, but especially for (2010) xc60s. Having an unbonded windshield seems like a significant hazard risk as the structural integrity of the entire windshield is compromised, as well as risk of electrical components getting wet as the water leaks through the car (and the ripple effects of that).
NHTSA complaint #11587676 — an unverified report by a vehicle owner.
The rear passenger door on this 4 year old car will not open from inside, nor outside. This is a huge safety issue, as any emergency egress from that point will not be possible. I can imagine the outcome if we were in an accident and needed to try to exit via that door. I chatted with Volvo and they simply recommended opening a case with their 800 number. I've seen forums with many other people having this same problem with Volvos for many years.
NHTSA complaint #11555887 — an unverified report by a vehicle owner.
After having my car for three weeks, the paint was permanently damaged by an inordinate amount of leaf prints and water stains. Even multiple rounds of polishing didn't fix the issue. Volvo claims this is not covered under warranty, as the damage occurred because of outside influences. I have a hard time believing they think this is an acceptable level of damage from a quite benign, normal level of outside exposure, especially because the dealership GM, the salesman, the detailer, and several car paint experts have never seen this before.
NHTSA complaint #11493711 — an unverified report by a vehicle owner.
June 4, 2022, 2018 Volvo XC60 - Right rear door lock engaged and would not release from either inside or outside door handle with all doors electronically unlocked. No other doors were affected. The door remained locked until Volvo technician removed inside door panel and made temporary repair on June 6. Replacement lock assembly was not available until Friday, June 10 when it was replaced by the dealer. Lock failure put safety of rear passengers at risk and I did not allow passengers in the back seat until lock was replaced. There was no warning lamp or message indicating lock failure. Dealer service representative said the failure mode was mechanical. Repair made under warranty.
NHTSA complaint #11468783 — an unverified report by a vehicle owner.
After I parked my car, the driver’s seat back tilted forward towards the steering wheel and could not be repositioned either manually or electronically. I could barely squeeze in and certainly could not drive the car with the seat in that position. The car needed to be towed to the dealer and Volvo replaced all related components, which were under warranty. If this had occurred while I was driving, the situation would have been extremely dangerous. There were no prior warnings of the seat back failure.
NHTSA complaint #11442178 — an unverified report by a vehicle owner.
The rain water leaking through windshield. It could cause rust in the frame, then cause the failure of whole structure. I checked the Volvo forums, seems there are many Volvo owners have similar issues. I owned other cars, it’s the first time I had leaking water through perimeter of windshield.
NHTSA complaint #11428956 — an unverified report by a vehicle owner.
My left front door failed to open using the outside handle. I have tried unsuccessfully to fix the problem by removing the inside door panel, the door window, and the surrounding hardware and electrical components. I contend that this is a safety hazard because a)a rescuer would fail to get the driver out of the vehicle in case of an accident and b)the door could open while driving because the latch contains a defective part. Other Volvo models have been recalled because of this problem, but my Vin number is currently not included in the recall. I contend that it should be recalled for my vehicle.
NHTSA complaint #11422492 — an unverified report by a vehicle owner.
WHEN RAINING OUTSIDE WATER DROPS INSIDE ON THE DRIVER FROM THE TOP OF THE WINDSHIELD ABOVE THE STEERING WHEEL . THIS JUST STARTED ON A 7.5 YEAR OLD CAR BUT WITH ONLY 47,850 MILES. THIS IS A SAFETY ISSUE BECAUSE THE DRIVER IS GETTING WET AND IS TOTALLY DISTRACTED AND, IF IGNORED, THE BODY WILL RUST, LOOSENING THE WINDSHIELD.. THE CAR CANNOT BE SAFELY DRIVEN IN THE RAIN WITH THIS LEAK AND IT CANNOT BE LEFT OUTSIDE AT ALL IF THERE IS ANY CHANCE OF RAIN, UNLESS THE WINDSHIELD IS COVERED WITH PLASTIC. IF I IGNORE THIS THE CAR WILL RUST AROUND THE WINDSHIELD SO AS TO WEAKEN IT'S ROLE AS A PART OF THE SAFETY CONSTRUCTION TO PROTECT THE OCCUPANTS IN A CRASH.
NHTSA complaint #11408026 — an unverified report by a vehicle owner.
WATER LEAKAGE INSIDE OF FRONT DRIVER SIDE WINDSHIELD DURING LIGHT RAINFALL. CAR WAS STATIONARY. LEAKAGE IS CONTINUOUS EACH TIME IT RAINS. VOLVO XC60 2013 3.2 ENGINE
NHTSA complaint #11398195 — an unverified report by a vehicle owner.
MY CUSTOMER WAS HEADED NORTHBOUND ON HWY 63, HAD JUST PASSED OVER I-70 WHEN THE CUSTOMER HEARD A POOF AND SMOKE STARTED BELLOWING FROM THE HOOD AND THE TAILPIPE. THEY PULLED OVER ON THE SIDE OF THE ROAD IMMEDIATELY, BUT BY THEN SMOKE WAS COMING OUT OF THE VENTS AS WELL. THEY GOT OUT OF THE CAR, AND CALLED 911 BECAUSE OF SMOKE STARTED TO THICKEN. ABOUT ONE MINUTE LATER, FLAMES STARTED COMING OUT FROM UNDERNEATH THE RIGHT (PASS) SIDE OF THE CAR AND WITHIN 25-30 SECONDS, FLAMES WERE COMING FROM UP UNDER THE HOOD AS WELL. THE FIRE DEPARTMENT GOT THERE AND PUT OUT THE FIRE. THE VEHICLE WAS TOWED BACK TO THE DEALERSHIP FROM THERE. THE CAR WAS IN PERFECT CONDITION. IT PASSED INSPECTION AT THE HONDA DEALERSHIP. WE DON'T KNOW WHAT HAPPENED OR WHAT WENT WRONG. WE DID SOME RESEARCH AND THERE WAS A RECALL NUMBER 09V477000; FUEL SYSTEM. THIS RECALL WAS SUPPOSEDLY FIXED BY VOLVO. WE CONTACTED VOLVO AND THEY SAID THAT THERE IS NOTHING THAT THEY COULD DO. HOWEVER, IN CARFAX THERE IS NO RECORD OF THE RECALL OR THAT THE RECALL WAS FIXED.
NHTSA complaint #11324184 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2018 VOLVO XC60. THE CONTACT STATED THAT THE DRIVER SIDE DOOR HANDLE ON THE INSIDE OF THE VEHICLE FRACTURED FOR THE SECOND TIME. THE VEHICLE WAS TAKEN TO (GUNTHER VOLVO CARS DELRAY BEACH 2201 N FEDERAL HWY, DELRAY BEACH, FL 33483) TO BE INSPECTED. THE CONTACT WAS INFORMED THAT THE BRAKE PADS AND ROUTERS WERE DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED AT THE OWNERS EXPENSE. THE MANUFACTURER HAD BEEN NOTIFIED OF THE FAILURE AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 21,300. *LN
NHTSA complaint #11307312 — an unverified report by a vehicle owner.
VEHICLE WAS IN THE HOLD POSITION, AS I WAS COMPLETING A TRANSACTION AT MY PNC BANK DRIVE UP. UPON LEAVING MY FOOT TORCHED THE ACCELERATOR LIGHTLY.SUDDENLY THE CAR STARTED TO ACCELERATE AT A VERY HIGH SPEED. I BRAKED BUT COULD NOT STOP. YOU COULD HEAR THE ENGINE REVVING. I CHOOSE TO HIT A LARGE TREE RATHER THAN ENTER A MAIN ROAD.THE CAR WAST TOTALED.
NHTSA complaint #11298948 — an unverified report by a vehicle owner.