Volvo Car USA, LLC (Volvo Car) is recalling certain 2020-2021 S90, 2020-2022 S60, V60, XC60, XC90, and 2022 V90 plug-in hybrid vehicles. The high-voltage battery may experience a short circuit within the battery module when the battery is fully charged and the vehicle is parked.
Volvo Car USA, LLC (Volvo Car) is recalling certain 2019-2022 V60CC, XC60, and XC90 vehicles. During steering gear assembly, double screws may have been assembled on top of each other, which can cause a screw to fall into the gearbox housing.
Volvo Car USA, LLC (Volvo Car) is recalling certain 2021 S90L, 2020-2021 XC60, and XC90 vehicles. An improperly welded rotor and shaft may separate within the integrated brake system.
Volvo Car USA, LLC (Volvo Car) is recalling certain 2021 XC40, XC 40 Recharge, V60CC, V90, V90CC, XC90, and 2021-2022 V60, XC60, S60 vehicles. The seat belt automatic locking retractors may deactivate early, which can prevent the child restraint system from securing properly. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 208, "Occupant Crash Protection."
Volvo Cars USA, LLC (Volvo Car) is recalling certain 2021 Volvo V60, V60 Cross Country, V90, V90 Cross Country, XC60, and XC90 vehicles. The Supplementary Restraint System (SRS) control unit may not have been properly attached to the car body and may detach during a crash.
The vehicle is experiencing repeated, unpredictable engine stalling while in motion and under active acceleration. The engine cuts out completely within 15–30 seconds or after several minutes of driving, without displaying any check-engine lights or diagnostic warning messages. This presents an immediate, severe safety hazard to the driver, passengers, and surrounding motorists on public roads. The vehicle is currently grounded as it is unsafe to operate.
No injuries · No fire · No crash
I am writing to urge NHTSA to address the serious safety problem caused by excessively bright headlights on American roads. Many LED, HID, high-mounted, improperly aimed, and aftermarket headlights produce such intense glare that oncoming drivers can be temporarily blinded. This can make it difficult to see lane markings, pedestrians, bicyclists, animals, curves, or stopped vehicles. At highway speeds, even a few seconds of impaired vision can have devastating consequences. Technology already exists to reduce this danger. Adaptive headlights can provide excellent visibility while reducing the amount of light directed at oncoming vehicles, and advanced systems have been used in other countries. Why is America lagging behind when safer technology is available? I urge NHTSA to strengthen regulations regarding headlight brightness, beam aim, mounting height, and aftermarket lighting, and to expand the use of glare-reducing technology. A driver’s ability to see farther should never come at the expense of another driver’s ability to see at all. Excessive headlight glare is not merely an inconvenience—it is a preventable safety hazard. Please take action to make nighttime driving safer for everyone.
No injuries · No fire · No crash
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.
No injuries · No fire · No crash
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.
No injuries · No fire · No crash
Hood latch assembly corrodes making it impossible to open hood or service the vehicle.
No injuries · No fire · No crash