2022 Volvo XC60

On [XXX], at 82,371 miles, my daughter's 2022 Volvo XC60 T8 Recharge was diagnosed with DTC BECM-P0BBD92 (Hybrid/High Voltage Battery Pack Voltage Variation) and a confirmed Cell Module F failure (Repair Order #[XXX], Bob Penkhus Motor Co Volvo Cars, Colorado Springs, CO). The dealer instructed her not to charge the vehicle pending repair. The replacement part (Cell Module F, Part #36003341) has been on indefinite backorder since diagnosis — initially quoted at 6 weeks, still unavailable as of this report. This vehicle falls within NHTSA Recall 25V-179 (LG high-voltage battery modules, fire risk when fully charged and parked). NHTSA's VIN lookup shows this VIN as having no unrepaired recalls, which I believe reflects only a prior software-monitoring update rather than a physical hardware fix — this diagnosed cell failure occurred after that update, is consistent with the exact failure mode described in the recall, and cannot currently be repaired because the remedy part is unavailable. Volvo Cars USA opened and then closed a corporate case (#[XXX], closed June 19, 2026) declining further assistance, stating its only obligation is to repair the vehicle — which it cannot presently do. It has been 138 days with no resolution on this matter. My name is [XXX] (father) and I can provide notarized authorization to act on my daughter's behalf on this matter. Thank you very much for your kind assistance. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Reporting a manufacturing defect in a 2022 Volvo XC60. The vehicle developed a metallic ticking noise in the timing area, audible at idle. Symptoms strictly match Volvo Technical Journal 36551.9.1 (NHTSA ID: MC-11015995-0001) regarding faulty camshaft seals. The noise disappeared when the oil filler cap was loosened, exactly as described in the TJ. An authorized Volvo dealer confirmed the defect and replaced the camshaft seals per Volvo’s protocol (Work Act No. ЗН-0131107). This repair completely resolved the issue, proving it was a manufacturing fault. The manufacturer refused warranty coverage citing 'salvage title' status, without proving any causal link between the title and this specific engine defect. Failure of timing components poses a significant safety risk, including sudden engine stall or oil leaks during operation. The owner was forced to pay out-of-pocket for the repair of a recognized factory defect. Supporting documents and video evidence are available upon request.

While driving on crowded I40 near Statesville NC, the engine started to stutter and moments later quit entirely. Fortunately we were able to move to the shoulder with only a few seconds to spare. This was very dangerous as we had to move through the right lane in front of speeding semi trucks. The only warning light received was that there was an engine problem, that the car would go into “safe” mode. This was mere seconds before entirely disabling the engine. Had we come to a halt on the highway there would have been a serious accident and injury to ourselves and most likely others. We contacted Volvo, a tow was dispatched and the car was winched on to a flat bed trailer and we were transported to a dealer in Hickory. Later it was confirmed that the Integrated Starter General (ISG) had failed and that power had been interrupted to the hybrid battery. There is a serious problem here and I suspect may impact other “mild hybrid” systems that install integrated alternator/starter motor systems between the engine and transmission.

Feb. 1, 2024: A short drive on electric during below zero weather, a car wash & a couple 100ft drive into a parking lot. Pulling into a parking space, foot on the brake pedal, ICE roared on accelerating the car over a curb, down an embankment & into a 3ft snow drift before I could stop it by pressing the brake pedal with both feet. We stopped 6in from a power pole. If forward crash avoidance system worked, didn't register in the EEPROM per the service tech! Feb. 17, 2024, during below zero weather, no electric charge, operating on ICE over about 2mi, Pulled into a parking space, foot on the brake pedal, ICE surged accelerating the car up over a 6" high curb onto sidewalk. Stopped car by depressing the brake pedal with both feet. Car stopped 2in before hitting a brick building. It didn't seem the forward crash avoidance system functioned to stop us. As a 35-year electronic design and repair professional, I have attempted to merge the two situations to try to find similarities. Two things: unexpected ICE engine acceleration surge & forward collision sensor not kicking on brakes. Per Volvo tech, Feb. 1, no register in EEPROM of forward crash avoidance or ICE issues. Second visit Feb. 22 to service will probably yield same. Obviously, this is not normal operation. We have been in two near collisions caused by the car doing things not designed to do.

I have recently experienced several episodes of the vehicle suddenly going into "limp home" mode while either accelerating onto or driving along at highway speed, causing a sudden loss of drive-ability and endangering me and my vehicle as well as those other passengers and vehicles traveling near me. I have taken it to the Volvo Dealer in Norristown , PA where I purchased the vehicle new less-than a year ago, and they said they have never seen the "Transmission Acceleration Performance Reduced" dash warning with the "turtle shell" icon or the DTC codes before, however, there is much discussion of this issue on the Volvo forums, and I respectfully request that you urgently look into this dangerous issue!

4 months old 2022 Volvo XC60 software bug that drained all batteries on board caused the vehicle to not to start, stuck in park, it was impossible disengage parking brake or put the car in neutral. Without any warning or battery low or battery empty indicator, the vehicle failed to start. We were put at risk by a car that can fail without warning and not start at all as we were stranded at a remote location. When the car failed to start, it could only be moved by a flat-bed tow truck, as it was impossible to put the car into neutral and it would not roll. The Volvo dealer confirmed that the vehicle failed to start because of a software bug. Dealer indicated that they were not able to start or move the car, they had to connect to it wirelessly and applied updates then reset battery and charge it for 4 hours, as the software bug caused the battery to drain without warning or indication, which provides power systems such as, starter, parking brakes and gear selections system. There were no warning indicators, messages or other symptoms of the problem prior to the failure.