2021 Volvo XC60

NHTSA received a petition on or about July 18, 2022, requesting that Federal Motor Vehicle Safety Standard (FMVSS) 141 be applied to all electric and hybrid vehicles operating in the United States. The petition can be reviewed at NHTSA.gov under ODI Number 11486072. FMVSS 141 establishes performance requirements for pedestrian alert sounds for motor vehicles. The standard applies to hybrid and electric vehicles that have a gross vehicle weight rating of 4,536 KG or less or are defined as low-speed vehicles. The standard became fully applicable to all such vehicles manufactured on or after March 1, 2021.On January 27, 2023, NHTSA opened Defect Petition (DP) 22-005 to evaluate the subject matter described in the petition. On June 24, 2023 and as supplemented on June 25, 2023, the petitioner notified NHTSA he was withdrawing his petition. The petitioner indicated that, based on his review of data, there is no justification for asserting potential benefits that could be derived from actions sought by my petition. Based on the petitioner's withdrawal, DP22-005 is closed. Closure of this DP does not represent a determination by NHTSA regarding the subject matter of the petition.

The air conditioning system in my 2021 Volvo XC60 failed, blowing hot air instead of cold. A Volvo dealer diagnosed the cause as a failed A/C evaporator core and quoted $7,800 to replace it. Volvo Cars North America has declined to provide any goodwill assistance despite this being a widely reported failure across multiple Volvo models (S60, S90, V60, XC60, XC90) at similar mileage/age, and despite Volvo having issued a running design change (a resistor harness, part no. 32241228) intended to prevent the evaporator core from over-cooling and freezing — indicating the manufacturer is aware of the underlying defect. Beyond the loss of cabin cooling, this failure created a separate safety concern: in warm-weather conditions, with the HVAC system unable to properly regulate cabin temperature, the vehicle's infotainment system began to overheat.displayed a thermal-warning message, dimmed/shut down, rebooted, or lost function while driving.] This is a safety issue because the infotainment display controls or is integrated with all functions of the car, and any unexpected shutdown, reboot, or loss of function of this system while the vehicle is in motion is a distraction and a loss of a driver-relied-upon system, particularly on a public roadway. This is also the second time I have experienced an evaporator failure of this type on a Volvo vehicle. My previous vehicle, a 2017 Volvo XC90, suffered an identical A/C evaporator failure on 6/6/2023. Two separate Volvo vehicles failing in the same manner suggests a systemic design or component issue rather than an isolated incident. I am filing this complaint to document the safety impact of this known defect and to request that NHTSA evaluate whether it warrants further investigation.

NHTSA ID

11766432

Incident

Aug 1, 2026

The A/C evaporator core on my 2021 Volvo XC60 suffered a premature structural failure, creating an immediate and severe safety hazard while driving. The component failed precisely five weeks after the Certified Pre-Owned (CPO) warranty wrapper expired. An authorized Volvo dealership service department formally inspected the vehicle and verified an active, heavy refrigerant leak utilizing UV filter video diagnostics. This component defect directly compromises vehicle safety in two distinct ways: Complete Loss of Windshield Defrost Capability: Due to the total failure of the climate control and dehumidification system, the vehicle completely loses its ability to clear the windshield during sudden weather shifts. During a period of heavy rain, the windshield instantly fogged over completely, severely restricting forward visibility and forcing me to immediately pull over on the shoulder to avoid a collision. Toxic Chemical Exposure: The cracked evaporator core continuously vents atomized chemical refrigerant vapor directly into the sealed passenger cabin through the HVAC ductwork. Even with the climate control system and fan completely powered off, a highly concentrated, sharp chemical odor filters into the cabin daily, exposing occupants to toxic chemical fumes while operating the vehicle. Volvo has documented this exact premature failure pattern across its SPA-platform vehicles under Technical Journal TJ 35912, explicitly acknowledging a systemic engineering defect where improper sensor calibration causes the core to freeze, warp, and crack. Despite knowing this part is prone to rapid premature failure, Volvo refuses to issue a safety recall, leaving drivers to operate unsafe vehicles or absorb an exorbitant $3,300+ out-of-pocket invoice to repair a known manufacturing flaw.

NHTSA ID

11766267

Incident

May 10, 2026

Hood latch assembly corrodes making it impossible to open hood or service the vehicle.

NHTSA ID

11759733

Incident

Aug 26, 2026

My SUV has a had the check engine light on from a failed battery cell for my 2021 grey Volvo XC60 recharge (VIN [XXX]). I have been without the electric functionality (to charge the hybrid car or use electric power) since mid December and waiting on a warranty part since Dec. 23, 2025. I have been told April 2026 and then August 2026 for this warranty issue that both the dealership and Volvo corporate have agreed is under warranty and needs replaced to make the car functional as intended. They claim the part as been backordered for the entire 8 months. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11756600

Incident

Dec 6, 2025

After backing up out of a parking space, the side mirror on the drivers side moves to an unpredictable position and does not return to its original position. This is potentially dangerous because the driver is not aware of this change in position, and when changing lanes may rely on mirror that is in a faulty position. This appears to be some sort of flaw in the logic that tilts the mirror down when backing up and returns to original position when the car is put back in drive. Regardless of whether I turn this feature on or off, the same malfunction occurs.

NHTSA ID

11753923

Incident

Jul 30, 2026

The entire right ride of the car just stopped working. Back right door became permanently locked and could not open from outside or inside. When hitting lock/unlock buttons on key fob i) front passenger door would not lock/unlock and ii) right side mirror would not fold in/out. Blind spot monitor and TPMS said they needed service. Left side of car was fine and worked. Car would start normally. I checked all relevant fuses and none were blown. Then all of a sudden it all started working again. My fear is that in the heat of summer what if all doors became locked somehow and i did not have the key fob with the manual key? I have 2 children

NHTSA ID

11747588

Incident

Jun 30, 2026

An intermittent electrical failure occurred to my wife causing my 2021 Volvo XC60 to stop and then later go into limp mode while driving. The service light went on immediately and was very startling to her and made it difficult for the drivers following as the car speed was significantly reduced/ I suspect limp mode though it was not on the dashboard. When I called Volvo and then brought the car in... it is a known issue to Volvo. They purposively produce a vehicle that is known for sunroof leaks which knowingly leads to electrical issues exposing their customers to harm. Volvo (Geely) inspected the car, found the electrical issues from the front interior to the battery compartment that had water over an inch deep. the VGM (Vehicle Gateway Module) was replaced and reloaded, all connectors were separate/dried and several had to be cut/spliced and rewired due to corrosion damage. Carpets were removed, the gasket was replaced, the front and rear sun roof drains were cleaned out. Aside from the safety concern the shrinking of the rubber gasket caused the issue. Not funny, but Volvo/Geely states that the repair now has a lifetime warranty after I was charged over $4,000 USD. The vehicle is only about 5 years old!!

NHTSA ID

11743000

Incident

May 29, 2026

My 2021 Volvo XC60 experienced a fuel system failure at approximately 53,500 miles. Prior to the failure, the vehicle displayed multiple warning messages and entered reduced-power (limp mode), including the turtle symbol on the instrument cluster. The vehicle unexpectedly would not start despite multiple attempts. The failure occurred while I was at a physical therapy appointment approximately 25 minutes from my home. After approximately 10 minutes, the vehicle started and was able to be driven. Because of the warning messages, limp mode, and failure-to-start condition, the vehicle was taken to a Volvo dealership for diagnosis. The Volvo dealership diagnosed the vehicle with ECM fault code P008A00 (Low Fuel Pressure). According to the repair invoice, testing confirmed that fuel pressure was intermittently low, and the dealership determined that the in-tank fuel pump was faulty. The fuel pump was replaced to correct the condition. This failure created a safety concern because the vehicle became unexpectedly inoperable and would not start when needed. Had the failure occurred in a remote location, during extreme weather conditions, at night, or in an emergency situation, it could have left the vehicle occupants stranded without reliable transportation. The inability to start the vehicle occurred without warning and could have resulted in a more serious safety risk under different circumstances. The issue was reproduced and confirmed by an authorized Volvo dealership, which inspected the vehicle, diagnosed the fault, and replaced the fuel pump. Repair records are available for inspection upon request. The failure occurred at approximately 53,500 miles, which is relatively low mileage for a major fuel system component. Because fuel pump failures can render a vehicle unexpectedly inoperable, I am submitting this complaint for review and investigation.

NHTSA ID

11741045

Incident

May 11, 2026

This is a TJ - text only no attachments - If customer complains of a headlamp error message in DIM, in combination with any of the DTCs stated below, follow advice under "Service".

This is a Technical Journal: Text plus 1 .jpg attachment - If remote control key is not detected by the car and shows message in DIM "Car key not found" or if functions such as lock/unlock are not working, please follow advice for detecting key

This is a Technical Journal: Headlamp condensation inside lens - information/leak test. If the result is not ok (air leak), it is ok to replace the headlamp

This is a Technical Journal: Intermittent knocking noise during acceleration. If the sound corresponds to attached sound file, change front drive shafts to the below part numbers.

This is a Technical Journal: Panoramic sunroof, sealing strip has a gap

This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure
 Description and Service sections updated to clarify that vehicle reports are not required.