2020 Volvo XC90 problems

“My 2020 Volvo XC90 plug-in hybrid is covered by Recall 25V-179 (Volvo R10312) for high-voltage battery cell modules that may short circuit and catch fire when fully charged and parked. On June 3, 2025, Volvo Cars Arrowhead performed the recall inspection and software update (Invoice 239958) and recorded “battery cell check ok no faults.” The vehicle was returned to us as remedied. On December 17, 2025, the same dealer serviced the vehicle (Invoice 244765) without flagging any open recall issue. On May 4, 2026, the high-voltage battery cell module failed and the system indicated "hybrid system failure." It was towed to the dealer, which diagnosed a failed cell module. Before it was towed, we drove and charged the vehicle at our home for about a week, with our children in the house. That is the exact scenario the recall warns about. The vehicle has been at the dealer for more than five months waiting for a replacement module, with no expected delivery date. On October 14, 2026, the dealer told us in writing that Volvo Cars USA had approved a software update as the “permanent fix,” that the failed cell module will remain in the vehicle, and that the vehicle can be…”

“2020 Volvo XC90 suffered a sudden catastrophic engine blowout, blinding exhaust smoke, and dropped to a 10 mph limp mode on the highway with zero prior dashboard warning lights or oil alerts. the vehicle lacks a manual dipstick, making the me entirely dependent on a digital safety warning system that failed. [XXX] Volvo has failed to give me any documents/ photos or proof of cost of repair for almost 60 days”

“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]”

“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…”

“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.”

“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…”