2020 Volvo XC90 problems

WHEELS

my vehicle has experienced a potentially catastrophic steering failure while driving, Volvo's authorized service attempts have not corrected it, and I no longer consider the vehicle safe.

NHTSA complaint #11758241 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

My 2020 Volvo XC90 T8 plug-in hybrid has been out of service for 78+ days due to a hybrid battery defect covered under an active manufacturer warranty (Claim Type XXX, valid through XXX). The vehicle was towed to Volvo Cars Arrowhead (Glendale, AZ) on XXX after a hybrid battery failure. The dealer confirmed in writing on XXX that multiple hybrid components require replacement and that parts are on extended backorder, and that Volvo Cars USA had authorized a rental vehicle because a loaner could not be offered "for an indefinite period of time." On approximately XXX, my service advisor advised me by phone that more than 700 vehicles nationally are waiting on the same backordered part and that the repair has no estimated completion date. I sent a formal written demand to Volvo Car USA ([XXX]) on XXX requesting repair by a firm date, a replacement vehicle, or repurchase. Volvo did not respond within the stated 14-day deadline or at any point thereafter. The defect appears related to NHTSA's existing recall action on 2020–2022 Volvo plug-in hybrid vehicles for high-voltage battery thermal runaway risk. I am filing this complaint to add to the federal record on this recall and to document Volvo's failure to repair an affected vehicle within a reasonable time or provide any remedy despite formal demand. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11752094 — an unverified report by a vehicle owner.

ENGINE

My 2020 Volvo XC90 T8 plug-in hybrid has been out of service for 78+ days due to a hybrid battery defect covered under an active manufacturer warranty (Claim Type XXX, valid through XXX). The vehicle was towed to Volvo Cars Arrowhead (Glendale, AZ) on XXX after a hybrid battery failure. The dealer confirmed in writing on XXX that multiple hybrid components require replacement and that parts are on extended backorder, and that Volvo Cars USA had authorized a rental vehicle because a loaner could not be offered "for an indefinite period of time." On approximately XXX, my service advisor advised me by phone that more than 700 vehicles nationally are waiting on the same backordered part and that the repair has no estimated completion date. I sent a formal written demand to Volvo Car USA ([XXX]) on XXX requesting repair by a firm date, a replacement vehicle, or repurchase. Volvo did not respond within the stated 14-day deadline or at any point thereafter. The defect appears related to NHTSA's existing recall action on 2020–2022 Volvo plug-in hybrid vehicles for high-voltage battery thermal runaway risk. I am filing this complaint to add to the federal record on this recall and to document Volvo's failure to repair an affected vehicle within a reasonable time or provide any remedy despite formal demand. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11752094 — an unverified report by a vehicle owner.

POWER TRAIN

This is my daughters vehicle. She was driving home from work with my [XXX] and [XXX] grandchildren in the car. The car suddenly wouldn't drive at a safe speed and was chugging along. She almost got into an accident because she couldn't go faster than about 12 mph. She as finally able to pull over in a safe location and called AAA. My son in law met her and picked her and the children up. The vehicle was towed to VOLVO in Buffalo NY. The diagnosis was a known leak in the sunroof that causes the drains to become blocked. Water then runs down and burned out the ECR module that is located beneath the drivers side foot well. Volvo is aware of the problem and is currently checking all vehicles for the blocked drains. They were given a 5000.00 estimate for repairs. Today VOLVO refused to repair it at their expense. There should be a full recall on this issue. I am a Fire/Explosion Investigator who has investigated numerous car fires related to Control modules catching fire. This could have caused a fire and trapped my grandchildren in the rear seat. The dealership reported 2 other vehicles in for the same issue. Please review and respond to me- [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11743304 — an unverified report by a vehicle owner.

VEHICLE SPEED CONTROL

This is my daughters vehicle. She was driving home from work with my [XXX] and [XXX] grandchildren in the car. The car suddenly wouldn't drive at a safe speed and was chugging along. She almost got into an accident because she couldn't go faster than about 12 mph. She as finally able to pull over in a safe location and called AAA. My son in law met her and picked her and the children up. The vehicle was towed to VOLVO in Buffalo NY. The diagnosis was a known leak in the sunroof that causes the drains to become blocked. Water then runs down and burned out the ECR module that is located beneath the drivers side foot well. Volvo is aware of the problem and is currently checking all vehicles for the blocked drains. They were given a 5000.00 estimate for repairs. Today VOLVO refused to repair it at their expense. There should be a full recall on this issue. I am a Fire/Explosion Investigator who has investigated numerous car fires related to Control modules catching fire. This could have caused a fire and trapped my grandchildren in the rear seat. The dealership reported 2 other vehicles in for the same issue. Please review and respond to me- [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11743304 — an unverified report by a vehicle owner.

ENGINE

This is my daughters vehicle. She was driving home from work with my [XXX] and [XXX] grandchildren in the car. The car suddenly wouldn't drive at a safe speed and was chugging along. She almost got into an accident because she couldn't go faster than about 12 mph. She as finally able to pull over in a safe location and called AAA. My son in law met her and picked her and the children up. The vehicle was towed to VOLVO in Buffalo NY. The diagnosis was a known leak in the sunroof that causes the drains to become blocked. Water then runs down and burned out the ECR module that is located beneath the drivers side foot well. Volvo is aware of the problem and is currently checking all vehicles for the blocked drains. They were given a 5000.00 estimate for repairs. Today VOLVO refused to repair it at their expense. There should be a full recall on this issue. I am a Fire/Explosion Investigator who has investigated numerous car fires related to Control modules catching fire. This could have caused a fire and trapped my grandchildren in the rear seat. The dealership reported 2 other vehicles in for the same issue. Please review and respond to me- [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11743304 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

The rear a/c evaporator coil has failed, leaking UV dyed green oil into the main battery pan. The a/c vents in the car in the driver and middle rows are now blowing hot air. This is a very commonly known problem with Volvo SPA XC90s from 2016-2021. It’s incredibly expensive to repair($3500 +). There should be a recall to replace/repair this problem in these relatively new and expensive cars.

NHTSA complaint #11737179 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

SUPPLEMENTAL TO NHTSA COMPLAINT #11713668. This is a supplemental filing regarding the 2020 Volvo XC90 T8 Inscription, VIN [XXX] . The hybrid battery cell module failed in December 2025, disabling the vehicle's hybrid propulsion system, all-wheel drive, and electric-only mode. As of this filing, the vehicle has been without hybrid functionality for over four months. The replacement part remains unavailable. Since the original complaint, the owner initiated civil proceedings against Volvo Car USA LLC and Volvo Car North America LLC in the State Court of Gwinnett County, Georgia (Case No. [XXX]). Through that litigation, the following facts have been established as deemed admissions under Georgia law, which neither Defendant contested: 1.This vehicle is excluded from Recall 25V-179, yet experienced a catastrophic hybrid battery cell module failure. 2.Battery failures in 2019-2022 XC90 T8 vehicles are not exclusively caused by the "LG supplier process deviation" identified in Recall 25V-179. 3.Volvo is aware of battery failures in 2019-2022 XC90 T8 vehicles outside the Recall 25V-179 population. 4.Volvo possesses internal engineering data showing the battery defect affects vehicles outside the population reported to NHTSA in Recall 25V-179. 5.Volvo has not issued a recall for the specific failure mode affecting this vehicle. 6.Expanding Recall 25V-179 to cover the full 2019-2022 XC90 T8 population would cost Volvo tens of millions of dollars. These facts were established against both Volvo entities through separate sets of Requests for Admission that went unanswered within the statutory deadline. The owner requests that NHTSA evaluate whether Recall 25V-179 is adequate to protect the full population of affected vehicles. Supporting documentation, including copies of the deemed admissions and service records, is being submitted by mail to the Office of Defect Investigation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11733717 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

SUPPLEMENTAL TO NHTSA COMPLAINT #11713668. This is a supplemental filing regarding the 2020 Volvo XC90 T8 Inscription, VIN [XXX] . The hybrid battery cell module failed in December 2025, disabling the vehicle's hybrid propulsion system, all-wheel drive, and electric-only mode. As of this filing, the vehicle has been without hybrid functionality for over four months. The replacement part remains unavailable. Since the original complaint, the owner initiated civil proceedings against Volvo Car USA LLC and Volvo Car North America LLC in the State Court of Gwinnett County, Georgia (Case No. [XXX]). Through that litigation, the following facts have been established as deemed admissions under Georgia law, which neither Defendant contested: 1.This vehicle is excluded from Recall 25V-179, yet experienced a catastrophic hybrid battery cell module failure. 2.Battery failures in 2019-2022 XC90 T8 vehicles are not exclusively caused by the "LG supplier process deviation" identified in Recall 25V-179. 3.Volvo is aware of battery failures in 2019-2022 XC90 T8 vehicles outside the Recall 25V-179 population. 4.Volvo possesses internal engineering data showing the battery defect affects vehicles outside the population reported to NHTSA in Recall 25V-179. 5.Volvo has not issued a recall for the specific failure mode affecting this vehicle. 6.Expanding Recall 25V-179 to cover the full 2019-2022 XC90 T8 population would cost Volvo tens of millions of dollars. These facts were established against both Volvo entities through separate sets of Requests for Admission that went unanswered within the statutory deadline. The owner requests that NHTSA evaluate whether Recall 25V-179 is adequate to protect the full population of affected vehicles. Supporting documentation, including copies of the deemed admissions and service records, is being submitted by mail to the Office of Defect Investigation. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11733717 — an unverified report by a vehicle owner.

POWER TRAIN

The contact owns a 2020 Volvo XC90. The contact stated that while driving 35-40 MPH, the message "Vehicle Not in Park" was displayed intermittently, and the vehicle stalled. The contact was able to pull over to the side of the road. The vehicle was restarted after several attempts and was driven to the residence. The vehicle was then taken to the dealer, where the contact was informed that no failure was found. The vehicle was not diagnosed or repaired. While investigating the failure online, the contact became aware that it was a common failure, and that the dealers were unable to duplicate the failure. The manufacturer was not notified of the failure. The failure mileage was approximately 79,000.

NHTSA complaint #11727942 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

The contact owns a 2020 Volvo XC90. The contact stated that while driving 35-40 MPH, the message "Vehicle Not in Park" was displayed intermittently, and the vehicle stalled. The contact was able to pull over to the side of the road. The vehicle was restarted after several attempts and was driven to the residence. The vehicle was then taken to the dealer, where the contact was informed that no failure was found. The vehicle was not diagnosed or repaired. While investigating the failure online, the contact became aware that it was a common failure, and that the dealers were unable to duplicate the failure. The manufacturer was not notified of the failure. The failure mileage was approximately 79,000.

NHTSA complaint #11727942 — an unverified report by a vehicle owner.

WHEELS

My tire somehow got a nail in it. I drove straight to Volvo when noticing the issue around 730am on 3/13/26. At 745am I spoke with [XXX] at Schumacher Volvo, he advised that they were too busy today to assist me. I advised I was afraid to drive with this and needed help and he told me to buy a tire lock kit and I could do it at another tire store. When I went to the parts department they advised the brake lock would not work and the only way to fix my tire would be to have Volvo remove the special lock nuts or replace them with common ones. Of course x they had no time to do this so they left me with zero options or ability to fix my car. I was forced to drive 30+ minutes home with zero solution. Completely unsafe and unfair I have absolutely no way to resolve this issue with my car. Unacceptable and scary considering Volvo claims they are all about safety but no concerns letting a single mother and her 2 children drive in a tire with a nail. XXX, INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11724311 — an unverified report by a vehicle owner.

SERVICE BRAKES

Vehicle: 2020 Volvo XC90 Mileage at first incident: ~60,000 miles Mileage at second incident: ~70,000 miles In July 2025, while my wife was driving our 2020 Volvo XC90 the vehicle experienced a sudden and complete loss of braking. The brake pedal did not provide stopping power, and the vehicle had to be steered off the roadway in order to come to a stop and avoid a serious accident. The incident created a serious safety risk. The vehicle was taken to an Wynn Volvo PA dealer and the brake booster and master cylinder were replaced at our expense (approximately $2,500). After the repair, the brake pedal initially felt abnormally soft and required a return visit for correct repair. Approximately six months later, in January 2026, while my teenage son was driving the same vehicle, the vehicle again experienced a complete loss of braking. Braking performance was lost without warning. He narrowly avoided a serious accident. The vehicle was brought to Wynn Volvo in PA and the hydraulic control unit (brake control module) was diagnosed as failed. Repair cost is approximately $3,000. This vehicle has now experienced two separate complete brake failures involving different hydraulic braking components within six months -- with both my wife and son narrowly avoiding serious accidents. Given that this is a safety-critical braking system failure with repeat occurrence, I am filing this complaint for investigation.

NHTSA complaint #11717769 — an unverified report by a vehicle owner.

ENGINE

In early December (2025), I experienced Hybrid System Failure, with the vehicle showing this fault in the dashboard and the check engine light coming on. I took it to the dealership, as the hybrid system is still within warranty, and they diagnosed a failed hybrid battery module. They said I could continue to drive the care in combustion-only mode and would order the module. Having heard nothing, I checked in early January and was told the module would not be available until May or June of 2026. I escalated to Volvo corporate. They opened a case and keep promising to have a manager reach out to update me, but they have failed to follow-through for almost a month. I am now faced with the prospect of operating an impaired vehicle that can't pass an emissions test (and which is under warranty) for more than half a year.

NHTSA complaint #11713668 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

In early December (2025), I experienced Hybrid System Failure, with the vehicle showing this fault in the dashboard and the check engine light coming on. I took it to the dealership, as the hybrid system is still within warranty, and they diagnosed a failed hybrid battery module. They said I could continue to drive the care in combustion-only mode and would order the module. Having heard nothing, I checked in early January and was told the module would not be available until May or June of 2026. I escalated to Volvo corporate. They opened a case and keep promising to have a manager reach out to update me, but they have failed to follow-through for almost a month. I am now faced with the prospect of operating an impaired vehicle that can't pass an emissions test (and which is under warranty) for more than half a year.

NHTSA complaint #11713668 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR:HANDLE:INTERIOR

If a passenger or child in the second row attempts to open a door before/while the doors are unlocked, the interior AND exterior handles no longer function. This can be temporarily fixed by doing a complicated and long random series of enabling/disabling electronic child locks and unlocking and re-locking the doors, but in an emergency situation it would not be possible. Passengers would be trapped in the case of a car fire or submerging event. This needs to be addressed by the manufacturer with a properly engineered lock that does not prevent the door handles from working if the handles are operated while locks are actuated! Here are two threads full of people with this issue: [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11707332 — an unverified report by a vehicle owner.

STRUCTURE:BODY:DOOR:HANDLE:EXTERIOR

If a passenger or child in the second row attempts to open a door before/while the doors are unlocked, the interior AND exterior handles no longer function. This can be temporarily fixed by doing a complicated and long random series of enabling/disabling electronic child locks and unlocking and re-locking the doors, but in an emergency situation it would not be possible. Passengers would be trapped in the case of a car fire or submerging event. This needs to be addressed by the manufacturer with a properly engineered lock that does not prevent the door handles from working if the handles are operated while locks are actuated! Here are two threads full of people with this issue: [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11707332 — an unverified report by a vehicle owner.

LATCHES/LOCKS/LINKAGES:DOORS:LATCH

The contact owns a 2020 Volvo XC90. The contact stated while attempting to open the rear passenger's side door from the inside or the outside of the vehicle, the door failed to open as intended, causing passengers to exit the rear driver's side door of the vehicle. No warning light was illuminated. The vehicle was taken to the dealer, where it was diagnosed and determined that the door lock kit needed to be replaced. The door lock kit was replaced; however, the failure persisted. The manufacturer was notified of the failure and filed a case. The approximate failure mileage was 71,000.

NHTSA complaint #11704687 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

The sunroof has leaked pouring water into the car. October 29, 2025 This is the second time this has occurred. First flood was January 3, 2023. Volvo covered the first repair done by a Volvo dealership. The current estimate to repair is $13,000 by the Volvo dealer. They have the car. The electronics have not been checked yet or are part of the estimate. It is unsafe to drive a car if the electronics may fail. I have filed a claim with Volvo and to date (42 days) there is no resolution. I cannot drive a car that fills with water when it rains. My daughter has a severe heart defect and cannot be in a car with mold and mildew.

NHTSA complaint #11704480 — an unverified report by a vehicle owner.

STRUCTURE:BODY

The sunroof has leaked pouring water into the car. October 29, 2025 This is the second time this has occurred. First flood was January 3, 2023. Volvo covered the first repair done by a Volvo dealership. The current estimate to repair is $13,000 by the Volvo dealer. They have the car. The electronics have not been checked yet or are part of the estimate. It is unsafe to drive a car if the electronics may fail. I have filed a claim with Volvo and to date (42 days) there is no resolution. I cannot drive a car that fills with water when it rains. My daughter has a severe heart defect and cannot be in a car with mold and mildew.

NHTSA complaint #11704480 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

The sunroof has leaked pouring water into the car. October 29, 2025 This is the second time this has occurred. First flood was January 3, 2023. Volvo covered the first repair done by a Volvo dealership. The current estimate to repair is $13,000 by the Volvo dealer. They have the car. The electronics have not been checked yet or are part of the estimate. It is unsafe to drive a car if the electronics may fail. I have filed a claim with Volvo and to date (42 days) there is no resolution. I cannot drive a car that fills with water when it rains. My daughter has a severe heart defect and cannot be in a car with mold and mildew.

NHTSA complaint #11704480 — an unverified report by a vehicle owner.

BACK OVER PREVENTION: SENSING SYSTEM: CAMERA

The camera system when backing up becomes unavailable intermittently. Sometimes it works and sometimes it doesn’t. System has been updated and restarted but it fails to fix the issue. When it happens it states camera unavailable and service required. Shutting off the vehicle and restarting multiple times sometimes corrects it. Automotive dealer said there is no issue with it. We have pictures of when it happens and the vehicle is available for inspection.

NHTSA complaint #11703455 — an unverified report by a vehicle owner.

VEHICLE SPEED CONTROL

The instrument panel just stopped working. Our safety and the safety of others was/is put at risk because you are unable to see how fast you are going in the car. It also doesn’t let us know how much gas we have left in the gas tank so if the car just stalled out on a highway, it could cause a major safety issue. This is also where cruise control is run from. It’s also the panel where any and all vehicle warnings would show up so if there’s another issue in the car, we are unable to see it.

NHTSA complaint #11658023 — an unverified report by a vehicle owner.