2021 Volvo XC40

I own a 2021 Volvo XC40 Recharge (pure electric). At 49,030 miles, while slowly driving in a parking lot, the vehicle suddenly began shuddering and jerking as if driving over rumble strips. A warning message appeared stating “Propulsion System Failure” and indicated the vehicle would reduce speed. The vehicle lost propulsion and came to a stop. After stopping, the vehicle would not re-enter Drive or Reverse and could not be driven. It was stuck in position in the parking lot but not in a parking space. The instrument cluster and infotainment systems still powered on, but the vehicle repeatedly displayed messages such as “Vehicle system check. Wait” and would not enter a ready-to-drive state. The vehicle had to be towed to the dealership with a dolly. It took 4 hours to move it because the first tow truck could not safely move it with the wheels stuck in place. This failure occurred without prior mechanical warning or other preceding symptoms. Dealer diagnosis identified an internal failure of the front axle inverter high-voltage assembly (IHFA). Service records document a 400A fuse failure, welded battery disconnect unit (BDU) contactor relays (R1 and R2), and overheating/damage to high-voltage battery disconnect components. Repair required replacement of the IHFA, BDU contactors, and high-voltage fuse. The dealership stated this was not a normal wear-and-tear issue. I have since found reports from other Volvo Recharge owners describing similar propulsion failures involving inverter and high-voltage battery disconnect components. My safety concern is the sudden loss of propulsion while the vehicle was in motion, with no warning and complete vehicle immobilization. Had this occurred at highway speed or in traffic, it could have created a serious collision hazard. The dealership service person agreed that my only chance to get the vehicle to a safe location was to coast. After that, it'd be stuck. I was unaware of this, which is itself an issue of concern.

The vehicle experienced a complete loss of propulsion, causing it to freeze and become unable to move. The first occurrence happened during the original factory warranty period and required towing to a dealership, but the root cause was not identified at that time. The same loss-of-propulsion failure has since recurred, rendering the vehicle inoperable. A dealership has now diagnosed a failure of an electric vehicle propulsion/inverter component. The vehicle is currently in the dealership’s possession and available for inspection. Loss of propulsion presents a safety risk, particularly if it occurs while driving or in traffic, as it can result in sudden loss of power and inability to move the vehicle out of hazardous situations. The failure has been confirmed by the servicing dealership. There is also concern that a related cooling system component may be involved, but that has not yet been confirmed, as the primary propulsion failure must be addressed first. As of the date of this complaint, the vehicle remains inoperable and has been at the dealership since mid-November awaiting repair authorization.

I was driving this car on Highway 99 on 7/11/2025. The dashboard flashed the message " Stop safely The vehicle will stop Propulsion system failure." I cut the lane and stopped my car on the Highway 99 shoulder. Just right, my car stopped on the Highway shoulder; it disabled itself and couldn't move at all. The gear shift can't shift to neutral (N). From the first message appearing on the dashboard to the car being disabled takes just a couple of seconds. When it happened, it was about 6:30 pm, rush hour. If I had not had a chance to drive the car immediately to the highway shoulder, the vehicle would have stopped in the lane, and I would have been crashed into by the cars behind me. This could lead to a catastrophic traffic accident. I want to mention that when the message appears on the dashboard, there is no sound alert. When people drive on the highway, their eyes are most likely focused on the road. Without a sound alert, people may not be aware of the message present. I contacted to the manufacturer on the 7/13, Sunday, they said they will open the case to investigation. As I report this incident, I have not heard from them yet. I uploaded the message photo that appears on the dashboard when the incident happened. Let me know if you need any information from me. Thank you!

In approximately May of 2023, my vehicle experienced "propulsion system failure" per a dash board light, and would not drive. I had it towed to Volvo and they told me that it was a known defect that required a software upgrade. They upgraded the software. In May of 2024, the car had a second propulsion system failure. The Volvo dealer found the error code and light on the dash, followed diagnostic procedures and saw that the software is up to date. They opened a case with Volvo and Volvo informed them that they are aware that propulsion system failures are occurring even with the updated software installed. They are planning an upgrade but have not yet completed it or made it available. Thus, Volvo knows that the propulsion system can fail, including when the car is in driving, and has not advised consumers or corrected the problem.

Very frequently (4-5 times a week) the charging cable will not release from the vehicle. Pushing release button resolves to flashing yellow, red, or green lights, but does not release. Sometimes will release from console, but not always. Locking and unlocking the vehicle, repeating all the above several times will eventually release the cable. This may be related to the erratic charging process where the car may or may not charge after being driven or left overnight. Dashboard may show initializing, or show that it is not charging when it is charging, or vice versa. Dealer stated could not duplicate, but software update would fix it. No code, no problem as they say in Sweden. Driving the 15 minutes home from the dealer resulted in the car failing to charge, and the cable refusing to release. This problem has been duplicated using a home Chargepoint charging system cable, and the supplied Volvo charging cable on two different 50amp outlets in the garage. The inability to remove the charging cable quickly in an emergency may lead to serious or even fatal consequences. A quick Google search shows that this is a known problem. There are other erratic system problems in the vehicle which by themselves may not be serious or fatal, but lead to increased driver distraction which could be serious or fatal.

Complete power failure of all electric Volvo XC 40 Recharge Vehicle has had recall update of software and additional software update. This is the second complete power failure Previously reported October 12 Recurrent power failure after "fix" on October 23. Volvo is unable to fix a complete power failure requiring tow truck to dealership.

On October 12, 2021 the above described car had a catastrophic failure of the power system. All functions ceased and the car was dead towed on a flatbed truck. Because the tow mode could not be engaged due to loss of all power the vehicle was dragged onto the flatbed. The repair indicated the cause was a The Battery Energy Control Module (BECM). This is noted in recall R10078. This car was sent for service in April where a request for a software update was made. At that service, no recall was noted and no update was given for this condition. There has been no attempt to recall this vehicle for this problem and it is not noted as a recall for this vehicle. The failure of the energy module caused a complete loss of all power and an inability to move the car.

A complete power failure. The main battery failed due to a software failure from The Battery Energy Control Module (BECM). The entire car stopped working. No power to unlock the wheels. The car was dead towed on rollers under the wheels via flatbed truck. A recall r10078 was not given and was not performed on prior visits to the dealer.