2021 Volvo XC90

Driving on a 45 mph road and brakes felt squishy, like air was going out of them. It was slow to stop and had to pump then stomp to get it to stop before crashing. Was fortunate to not hit anything. Pulled into gas station and had it towed to Volvo. There were no warning lights or other indication of problem- the brakes just failed. Volvo said the vacuum pump failed which pushed oil into the brake booster causing it to fail. The car has 74,000 miles and has been serviced regularly.

My 2021 Volvo XC90 Recharge has experienced multiple hybrid system failures under Volvo's factory 8-year/100,000-mile hybrid warranty, with fewer than 45,000 miles on the odometer. The high-voltage battery modules have failed multiple times, directly related to recall R10312 (NHTSA 25V-179), which identifies a supplier process deviation in LG battery modules creating a risk of internal short circuit and thermal runaway — an acknowledged fire risk. Critically, my vehicle has suffered two actual battery module failures, not preemptive recall replacements. This places my vehicle in a substantially higher risk category than others in the recall population with no prior symptoms. A vehicle that has already experienced the exact failure mode identified in a safety recall presents a materially greater ongoing safety risk. Additionally, my vehicle suffered a complete ERAD (Electric Rear Axle Drive) failure — a known defect that Volvo acknowledged by releasing a redesigned ERAD2 unit, confirming awareness of this systemic issue. These repeated failures left my vehicle un-drivable and parked at the dealership for more than 6 months, with replacement parts repeatedly placed on backorder, causing severe and prolonged loss of use. I filed a formal complaint with Volvo Customer Care requesting a vehicle buyback. After months of inadequate communication, Volvo declined to buy back the vehicle or offer reasonable trade-in accommodation. Instead, Volvo offered a nominal monetary concession contingent on signing an NDA, which I declined as insufficient given the documented safety risk, repeated failures of a recalled component, extended loss of use, nor out of pocket car rental expenses. I am filing this complaint to ensure my vehicle's actual failures are part of the NHTSA record for R10312/25V-179, and to request NHTSA evaluate whether Volvo's response to owners who have experienced actual failures — rather than preemptive recall repairs — warrants further regulatory scrutiny.

The ERAD (Electric Rear Axle Drive) transmission on my 2021 XC90 T8 Recharge has suffered an internal failure at approximately 112,550 miles. The vehicle makes loud grinding and slamming noises from the rear drivetrain and locks up when attempting to drive, making the vehicle completely undrivable. The dealership (Volvo Cars Gilbert, AZ) diagnosed the ERAD clutch as slamming and suspects internal gears are missing teeth. A software update was attempted but did not resolve the mechanical failure. The ERAD transmission needs full replacement at a quoted cost of $5,211.56 (part number 32324105-9). This is a known failure point on the T8 platform and Volvo has redesigned this component (ERAD2) for newer models due to reliability issues with the original design. This failure presents a safety concern as the rear drivetrain can lock up unexpectedly during driving. This ERAD failure occurred alongside two other hybrid system component failures within a 3 month period: the High Voltage Coolant Heater (HVCH) and the vehicle batteries (VCM and main), suggesting a systemic hybrid system reliability problem.

The contact owns a 2021 Volvo XC90. The contact stated that upon starting the vehicle and shifting to drive(D), the vehicle failed to respond unless the brake pedal had been released for 2-3 seconds. Additionally, the contact stated that upon starting the vehicle and releasing the brake pedal to reverse out of the driveway, the vehicle rolled back at a faster speed, and the vehicle failed to respond as intended upon depression of the brake pedal. The contact noticed a pattern with the brakes malfunction. The contact stated that the brake pedal required to be depressed 2-3 seconds after the first depression for the brakes to operate as intended. The contact stated that he was a master mechanic and had concluded that the failure was considered a safety issue because the vehicle was only designed with electronic braking, which left the driver with no manual option for braking. The contact stated that the failure had only occurred upon starting the vehicle. The contact related the failure to NHTSA Campaign Number: 25V392000 (Service Brakes, Hydraulic, Service Brakes); however, the VIN was not included. The vehicle was taken to the dealer, where it was diagnosed that the brakes had failed and Software Update Number: 3.5.14 was needed. The vehicle was not repaired. The manufacturer was informed of the failure, and it was confirmed that the repair was not covered under the recall or under warranty. The failure mileage was approximately 78,500.

The vehicle’s Start/Stop system began displaying warning messages and malfunctioning prior to the expiration of the factory warranty. The issue first appeared before 50,000 miles and reappeared at 49,997 miles, when a warning was displayed on the dashboard. The vehicle was taken to an authorized dealer for inspection. A diagnostic review confirmed the need to replace the Start/Stop auxiliary battery and repair the Park Assist system. A diagnostic fee was charged, and both system failures were documented. The Start/Stop system’s failure raises a potential safety concern because the vehicle may not reliably restart after automatically stopping at intersections or in traffic. This could lead to dangerous situations if the vehicle stalls unexpectedly or fails to re-engage power at a critical moment. Although the issue has not caused a crash or injury, it introduces unpredictable behavior that could compromise safe operation. The Park Assist system also failed, triggering system warnings and disabling parking assistance features. If a driver is relying on these systems during low-speed maneuvers, a sudden or silent failure may increase the risk of collision with objects, pedestrians, or other vehicles. The dealership confirmed the problem through inspection and diagnostic testing. The manufacturer was contacted and declined to cover the repairs under warranty, despite the vehicle being within the mileage limit when the issue was first documented and presented for service.

Title: Possible Defect – Uneven Airbag Deployment Description: On July 20, 2025, around 5:30 PM, i was driving a 2021 Volvo XC90 on a main road when another vehicle suddenly entered from the right side without stopping at a stop sign. I was unable to avoid a collision and my vehicle T-boned the other car (front impact on my vehicle). During the crash, I believe the front airbag system did not deploy properly or deployed unevenly. I felt like the left side of the airbag (from the steering wheel) was full of air but not the right side (that side was flat when it deployed), and I believe I hit my head on the steering wheel. I experienced severe injuries to my head, face, and right eye, including commotio retinae, lens displacement, corneal abrasion, corneal edema, phacodonesis, iridodonesis, and concussion. I am concerned that the Supplemental Restraint System (SRS) malfunctioned, contributing to the severity of my injuries. No modifications have been made to the airbag system. I request that NHTSA investigate whether there is a defect in the airbag deployment of the 2021 Volvo XC90, particularly for asymmetric or partial deployment. The automatic emergency braking (AEB) system also did not activate despite the imminent collision. There were no warning lamps, messages, or unusual symptoms prior to the crash. The issue has not yet been reproduced or confirmed by a dealer or service center, but The police was at the scene. My insurance company has inspected the vehicle. I have also reported this to the customer care team at Volvo.

I plugged my usb to usb-c charging cable into my iphone 20 seconds after starting the vehicle. I proceeded to exit my driveway when the infotainment screen went completely blank and the same thing to the driver's display 10 seconds later. I drove to the end of my street to a stop light where the car completely shut off and automatically restarted within a few seconds. I was traveling with my wife and [XXX] daughter. I have yet to reproduce the problem but have an appointment scheduled with the dealership later this week. Zero warnings or messages were present before, during or after the incident. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The brakes did not work when the automatic emergency braking turned on. When I pressed the brakes all the way down, the brakes didn’t respond because it was still in automatic mode. I was able to swerve into the next lane to not hit the vehicle in front of me. The automatic emergency braking also turned on when I was reversing from a parked location when there was a vehicle waiting to park behind me and my vehicle stoped and didn’t come off of brake/park mode. I had to turn my vehicle on and off again to get it to move again. I have taken my vehicle in twice for shaking. My back rotors were replaced 2 weeks ago but my vehicle still shakes. This car only has around 21,000 miles to have so many issues already with rotors and shaking.