Volvo Xc60 Recalls

The Volvo XC60 has 35 recalls spanning the 2009–2025 model years, with the most serious recent issue being a steering gear assembly defect on 2019–2022 models where a misplaced screw can fall into the gearbox housing and lock the steering wheel, causing a sudden and complete loss of steering control.

On the most current production years, 2022–2025 models have a software fault that can prevent the rearview camera from displaying when the vehicle is shifted into reverse. The 2023 model year has two separate software issues: a brake control module error that can disable anti-lock brakes, stability control, and traction control, and a false warning that can mask a real failure in the emergency call system. On 2022–2023 plug-in hybrid and mild hybrid models, an engine control module software error can prevent the combustion engine from starting and drain the high-voltage battery, causing a loss of drive power while in traffic. Front seat mounting bolts may be loose on 2025 models, preventing the seat from holding an occupant properly in a crash.

The 2020–2022 plug-in hybrid models carry a high-voltage battery recall where a short circuit can develop while the vehicle is parked and fully charged, raising the risk of fire. On 2020–2021 models, a brake system component with an improperly welded rotor and shaft can separate, reducing braking assistance and disabling anti-lock brakes and stability control. The 2021 model year has a restraint system control unit that can detach from the body in a crash, degrading airbag, seatbelt, and high-voltage battery disconnect performance. Seat belt retractors on 2021–2022 models can deactivate too early, preventing child safety seats from being secured properly. The 2019–2020 automatic emergency braking system can fail to detect obstacles due to a software and hardware incompatibility. A low-pressure fuel pump fuse failure on 2019–2020 models can cause the engine to stall. Loose wiper arm nuts on 2018–2020 models can cause the wipers to slip out of position and fail to clear the windshield. The 2018–2019 models have two separate issues: power tailgate lifting arms that can freeze and separate in cold weather, projecting rearward with force, and front seat rail mounting nuts that may be missing, allowing the seat to shift in a crash.

Going back to the 2016–2017 era, the front passenger seatbelt buckle on 2016–2017 models can separate from its bracket, leaving the passenger unrestrained in a crash. The 2017 model year has side airbag inflator initiators that can fail to ignite, preventing deployment in a crash. A starter motor fuse on 2016 models can blow during automatic engine stop/start operation, leaving the vehicle unable to restart in traffic. A connectivity module software error on 2017–2019 models can prevent accurate GPS location from being transmitted to emergency services after a crash.

The 2009–2016 model years share a front seatbelt pretensioner recall where the retractor can fail to properly restrain an occupant in a crash. The 2012 model has an underbody coating that can form rigid, icicle-like protrusions hanging from the undercarriage and damage the fuel lines, causing a fuel leak. On 2010 models, exposed fuel lines due to an improperly attached underbody cover can be damaged and leak fuel near ignition sources.