2020 Volvo XC90 Problems

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)

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)

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)

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)

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)

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.

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.

The issue started a few months ago. The brake sensor light on the dash turned on and stayed on. We took it to the dealer and they said that they will not fix it because they can see coffee stains on the sensor. Basically they have brake sensors right under the center console where people drink coffee and the brake sensors are exposed so this can happen to any customer. Now they want to charge us 1600 dollars even though the SUV is about 2 years old and under full warranty. They want to screw their customers and don't care about their safety. This is the brake system of the car and now it's having issues with the adaptive cruise control inwhich the system turns off while in use. We are concerned about our safty and don't know what to do.

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)

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.

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)

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.

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)

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.

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)

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.

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)

The contact owns a 2020 Volvo XC90. The contact stated that after plugging in the charger to the vehicle, the cable charger started blinking red. The contact had to jumpstart the vehicle to open the doors. The blinking red light on the cable charger had not stopped blinking. The contact related the failure to NHTSA Campaign Number: 18E086000 (EQUIPMENT); however, the VIN was not included in the recall. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was unknown.

PURCHASED A NEW 2020 XC90 T6 INSCRIPTION WITH THE AIR SUSPENSION. FROM THE FIRST TIME PULLING INTO OUR DRIVEWAY, THERE WAS A DISTINCT, MUFFLED, AGGRESSIVE "THUMP" IN THE FRONT AND REAR END. THE SOUND IS INDEPENDENTLY FROM THE FRONT OR REAR SUSPENSION, DEPENDING ON WHICH IS GOING OVER A BUMP. THIS OCCURS CONSISTENTLY WHEN IN SLOW SPEEDS AND GOING OVER AN ABRUPT BUMP, SUCH AS A SPEED BUMP OR AN AGGRESSIVE CUT OUT IN A DRIVEWAY WHICH IS MADE FOR WATER RUN OFF. ONCE THE SUSPENSION COMPRESSES, THE THUMP OCCURS ON DECOMPRESSION (REBOUND). I TOOK IT INTO THE ORIGINAL DEALER (VOLVO OF TUCSON). A 2019 XC90 T8 MOMENTUM (WITH AIR SUSPENSION) WAS GIVEN AS A LOANER. AS EXPECTED, THE LOANER VEHICLE MADE THE EXACT SAME THUMP SOUND FROM THE FRONT AND REAR SUSPENSION OVER THE EXACT SAME BUMPS. THE DEALER COULD NOT REPLICATE THE SOUND ON MY CAR. I PROVIDED THEM WITH NHTSA ID #'S: 10148803 AND 10128173 (VOLVO BULLETIN #'S: TJ32978 AND TJ3303.1.1). NO RESPONSE YET AS TO THE PROBLEM OR CORRECTION. *TR

The vehicle shudders randomly when taking off from a stopped position around 18mph. The vehicle shudders randomly when slowing down to make a right turn. The vehicle shudders when driving at higher speeds. It's not a violent shudder, but those riding in the vehicle feel it as well. The safety concern is two fold in that there is a fear of losing control at an inopportune time. Secondly, the constant shuddering over time is going to result in damaging other part of the vehicle, particularly the engine, that will present a safety hazard while driving. The vehicle was purchased used(certified). The dealer replaced collapsed engine mounts on left and right side and considered it resolved. Forman at dealer stated it is common with XC90's to have engine shudder as if this should be accepted. Because the engine shudder is happening at higher speeds now, we're going to return to dealer, but I do not expect a solution. I've seen others report similar issues with shuddering on Volvo forums and I haven't seen 1 solution that worked. This is a problem in a lot of XC90's. The attached documents also contain some attempted fixes to correct a drifting issue.

The airbag system detected a fault and caused an automated vehicle warning message, which, with further dealer diagnosis, caused the driver seat belt to have a ground fault issue, preventing the normal, safe, and fully operating vehicle airbags. The cause and what must be replaced to rectify the problem are unknown. Volvo has poor customer support and satisfaction regarding avoidable repairs, along with various documented airbag failure incidents confirming a severe issue with its system components that require government oversight and correction through a recall to ensure the safety and reliability of the safety systems that protect lives.