2019 Volvo XC60

Our Nest Protect woke us at 06:30 am saying it was detecting smoke in the garage. Upon entering the garage it was obvious that the cabin of the car was filled with white smoke. Disconnected car from charger port. Attended to drive car out of garage to protect the house, but opening the door just let smoke billow out. Closed the door and called 911. Fire truck arrived - the winched the car out of the garage to protect the house. Using their thermal imaging camera determined the hybrid battery was the hotspot, not any of the charging connections. They ran water into back seat where that battery is located for over two hours to keep it from pop further thermal runaway. Clearly an internal EV battery short. Fire fighters had a sensor and detected residual HCN (hydrogen cyanide gas) and I had to be treated at the ER as a precaution as I inhaled a large amount of smoke when I opened the car door initially.

Let me Preface this with, my Make, Model, and year for these problems have been recalled back in 2021, however I was not the owner then and my VIN was not listed as an affected vehicle i guess, nonetheless the problem is exactly the same as experienced by those that were listed on the recalls in the past. Im the 2nd owner of this vehicle and I have owned it for almost 3 years now. In July 2025 after a summer rain in so. cal, I was a couple blocks from home running errands and after being stopped at a light, i began to accelerate and felt like the vehicle was loosing power, I made it home but definitely not able to go the speed limit and once i got home I couldnt shift it into any gear and the vehicle would not turn off. So I had to remove the fuses under the hood, I left them out for a few hours and let the car sit off in my garage during that time. I later came back put the fuses back in and then the car wouldnt turn over. I had it taken to the dealership by AAA and thats when i first learned of the sunroof leak, I contacted Volvo Headquarters and got no help and explained all of the same to the service dept at the dealership working on my car. Long story short the dealership allegedly found water under my interior carpet which obviously damaged modules, I am still paying on that repair. Fast forward to October 2025, same thing all over again only this time the dealership tells me essentially its on the house, however they had my car 3 weeks and did no repairs only got water out of it once again and “brushed off some corrosion”. When I pick it up, it immediately starts funny, i turn the car off and walk right back into the service dep t& raise my concern, to which i was told they had no problem with a hard start up, and we go out to my car & it starts up fine, so i leave 4 days after I got my car back, the check engine light comes on, & immediate warning of reduction of engine power & sure enough thats what it did. today it enters safety mode & wont start

On 9/1/25 while driving 25 mph in the neighborhood the car started shifting very hard. Upon getting back in the driveway and put in park all dashboard light came on. Car would not leave park, parking brake would not work. Windows would not roll down, dash would not turn on, car would not turn off. Got it to the dealership and the told me it was a software update that needed to be done.

I am submitting this report to formally document a significant safety issue involving the Driver Display Module (DIM) on my Volvo XC60. Prior to reaching 45,000 miles, the DIM began to intermittently glitch, displaying only a barcode-like screen. This eventually progressed to complete failure of the unit with complete lack of digital driver display without analog back-up. As a result of this malfunction, all critical vehicle information became inaccessible, including the speedometer, odometer, fuel level, gear selection, and dashboard warning indicators. This failure severely impairs the driver’s ability to safely operate the vehicle, as it removes access to essential operational data necessary for safe driving and decision-making. I reported this issue to Volvo Customer Support, but they were dismissive of the concern and offered no meaningful resolution. In researching the problem, I found multiple similar complaints documented in online automotive forums, suggesting that this is not an isolated incident but rather a recurring defect among Volvo XC60 vehicles. Given the safety-critical nature of the driver display and the fact that this failure occurred in a relatively low-mileage vehicle, I believe this issue warrants investigation by NHTSA. The frequency of these failures and the serious risk they pose to driver awareness and vehicle control support the need for a safety recall. Thank you for your attention to this matter.

Any switch on the right side of the steering wheel - Up/down/Left/Right/Center switches not functioning or intermittently functioning. It is available for inspection upon request As the buttons are not warning, any signs or anything which comes on the center display cannot be removed or moved The vehicle or component has not been inspected but the technical journal (REF NO: TJ 32033.5.0) for the same was issued - [XXX] There are other forums who have brought the same issue as well [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The moon roof leaks and drains into the area of the electronic gateway. This causes the car to become inoperable, slowing it to a crawl, once in park it will not get out of park, and sometimes results in not being able to turn off the engine. Many error codes become displayed ranging from no parking brake available, ESB not responding, check engine light, and others. According to user forums, this issue has been around since 2017 for many of the models and Volvo will do nothing to repair it or acknowledge it. I have paid $2250 so far and the vehicle is still unusable.

Water intrusion via a faulty sunroof seal and drain system. Water drains into the vehicle and collects under the flooring carpets and is not detectable. Water then disables and shorts out electrical components and computer modules eventually rendering the vehicle completely inoperable … including airbags, suspension system and electronic engine components. All control is lost. System also displays a number of random and often times confusing and erroneous error message to display console. This is an extremely dangerous problem, and extremely expensive to remedy, and appears to be related to a significant design flaw. According to internet reports, this is a known issue. Dealer is the one who diagnosed the problem. Given this problem affects electronics - there is a threat of fire.

The drainage system from the roof of the vehicle is faulty and causes water to collect in the space between the carpet in the interior of the vehicle and the floor of the vehicle. Key electrical components are located beneath the front passenger seat of the vehicle. When the water collected, it caused key systems, such as collision warning and other systems to malfunction. When we took the vehicle to the dealership, several other vehicles had to be towed in due to more severe electrical failure as a result of the drainage malfunction.

Driving down the interstate in rush hour at 30 mph, the entire entertainment system as well as the dashboard went black and went through a system restart. The dashboard, including spedometer and related controls were black and unusable for approximately 10 seconds. Approximately 3 minutes later, the system reboot again and all visual aids were unusable for 10 seconds or so.