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)

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 purchased the car in April 2022. Did not have any issues until February 2023. Initially, the engine light came on with a turtle icon in the dash screen. I was driving and the car would not go over 45 mph. on a busy street . The car was hesitating badly and also said something about the propulsion? Volvo Ontario towed it from my business and supposedly fixed it. Fast forward the following week, engine light came. Back to dealer, who said the software at that time was not available and it was a recall. A few days later they said they were disconnecting the engine light until new update was available. Back to dealer with update now installed, supposedly this would fix all the engine issues. A few days later, 3/7 I got into car and started it . This mesage came on, "Slow down, the vehicle will reduce speed. Propulsion system failure", Followed by ,"Propulsion System Service Required" with yellow engine light on. Backed out of the driveway and the car started vibrating and shaking violently. Currently waiting on Volvo for next steps. I am so dissapointed with this car and it is a huge concern for safety. I purchased this car because of their reputation for safety.

I was driving on a highway over 55 MPH when the Power Limitation Indicator symbol, the red warning symbol and the Emission control system flashed on which immediately limited my maximum speed to 45 MPH. This instant deceleration in high-speed traffic almost caused the car behind me to rear-end my car. I put on my flashers and exited the highway ASAP. The error light stayed on until the car's electric battery had been drained and the gasoline engine was being used 100%. Two weeks later the Power Limitation Indicator symbol flashed on again but this time I was on local roads traveling at 35 mph thus the car did not decelerate. Again, after draining the car's electric battery the Indicator symbol went away. What component or system failed or malfunctioned, and is it available for inspection upon request? Propulsion System and yes How was your safety or the safety of others put at risk? The instant deceleration of the vehicle in fast moving traffic was a potential accident situation. Has the problem been reproduced or confirmed by a dealer or independent service center? The dealer cannot replicate the error message nor knows how to fix it. Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? Yes, the Propulsion system service required warning symbol and message.