2021 Volvo XC90

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.

Electrical system shutdown during use rendering car unable to shift out of park. According to dealer, the extensive electrical and wiring damage resulted from a clogged sunroof drain. This issue is well documented for a decade or longer and is clearly a safety problem (vs "maintenance" or "wear & tear") as vehicles are rendered useless on the roadway. I do not understand why NHTSA has not issued a recall. Is this NHTSA Mission Statement no longer relevant? "NHTSA'S MISSION Save lives, prevent injuries and reduce economic costs due to road traffic crashes, through education, research, safety standards and enforcement activity."

NHTSA ID

11775592

Incident

Oct 31, 2026

The rear passenger-side door latch on my 2021 Volvo XC90 failed, and the door will not open from inside or outside. This prevents an occupant from exiting through that door, including in an emergency or after a crash. The failure occurred on XXX at approximately 45,000 miles while the vehicle was in normal use. I have small children and they are now not able to get out of the car so this is a major safety issue. There was no crash or injury. Borton Volvo ([XXX]) diagnosed a failed door latch assembly and quoted $1,106 to replace it. Volvo declined goodwill coverage. Owner reports indicate door latch failures are common on 2016+ XC90 models INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11774410

Incident

Oct 1, 2026

The check engine light on our Volvo XC90 Plug-in Hybrid came on stating "Hybrid System Failure Service Required". The vehicle would no longer accept a charge. A service appointment was made and the technician found that there was a fault with cell module A. A case was started but we were told the part was on backorder.

NHTSA ID

11771735

Incident

Nov 1, 2025

The chrome trim on the center console, immediately to the right of the gear selector, deteriorates and peels away, leaving razor-sharp edges capable of cutting skin. This appears to be a widespread issue, with numerous owner reports and photographs online dating back to the 2016 Volvo XC90. The same defect is present on my 2021 model, suggesting Volvo has continued using a component prone to this failure for multiple model years. The location is particularly concerning because drivers frequently place their hands near this trim when operating the gear selector and using the center console. Owners have reported cuts and bleeding from the sharp edges, creating a potential risk of sudden driver distraction. This is a recurring safety concern involving a factory-installed component, not simply a cosmetic defect, and warrants investigation by NHTSA.

NHTSA ID

11770384

Incident

Oct 3, 2026

This is 2021 volvo xc90 purchased new in 2021. A few weeks ago, my wife asked me to look at the middle row seatbelt as it wouldnt buckle. I could see that it was broken. I checked the seatbelt next to it and same thing. Plastic buckle broken in same place. I took it to the dealer where we get serviced and they told me it would cost $900. I told them this should not be my expense as this is a manufacture defect. Car was bought new 5 years ago. I brought the car home and then checked all seatbelts. 4 out 6 (have a third row) all have the same issue! I created a case with Volvo corporate. I was offered a 20% discount on parts only. I told them this was unacceptable and they then closed the case as they said i declined their assistance. Dealer told me it would cost about $1500 to repair all 4.

NHTSA ID

11769047

Incident

Aug 22, 2026

My 2021 Volvo XC90 Recharge (plug-in hybrid) has been at Volvo Cars Dublin, Dublin CA since June 15, 2026 for a failed high-voltage battery cell module requiring replacement. The replacement part is on national backorder with no estimated availability. The vehicle has been out of service for over 100 days and remains undrivable. A failed high-voltage battery cell module in a plug-in hybrid is a safety concern, and the indefinite nationwide backorder suggests this defect and parts shortage may affect other owners. Volvo corporate (case 07207782) has provided no repair date.

NHTSA ID

11766833

Incident

Jun 15, 2026

My 2021 Volvo XC90 Recharge (plug-in hybrid) has been at Volvo Cars Dublin, Dublin CA since June 15, 2026 for a failed high-voltage battery cell module requiring replacement. The replacement part is on national backorder with no estimated availability. The vehicle has been out of service for over 100 days and remains undrivable. A failed high-voltage battery cell module in a plug-in hybrid is a safety concern, and the indefinite nationwide backorder suggests this defect and parts shortage may affect other owners. Volvo corporate (case 07207782) has provided no repair date.

NHTSA ID

11766832

Incident

Jun 15, 2026

The contact owns a 2021 Volvo XC90. The contact stated that while driving at various speeds and depressing the accelerator or the brake pedal, the vehicle hesitated with the check engine warning light illuminated. The dealer was contacted. The vehicle was taken to the dealer to be diagnosed, and it was determined that the electric rear axle drive system had failed and needed to be replaced. The contact stated that the failure occurred each time the vehicle was driven. The manufacturer was notified of the failure and informed the contact to continue driving the vehicle because the vehicle was safe to drive. The failure mileage was approximately 60,000.

NHTSA ID

11765838

Incident

Sep 1, 2026

Mileage

60,000 mi

This is a Technical Journal text only no attachments : Improved 12V battery test in VIDA. The 12V battery test in VIDA has been improved. The improved test lets you check batteries below 11.5V with the battery in the vehicle and a shorter test time. (Follow the instructions in VIDA)Don´t charge the battery before the test, jump start the vehicle if needed. Read out the vehicle with VIDA and start the test.

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.