Summary
The Volvo XC60 has 17 recalls spanning 2010 through 2021, with the most serious recent issue being a brake system defect on 2020-2021 models where an improperly welded rotor and shaft can separate inside the integrated brake unit, reducing braking assistance and disabling anti-lock brakes and electronic stability control.
A separate brake concern on 2020 models involves brake pedal connecting rods that can loosen over time, changing pedal feel and extending stopping distances. Rounding out the recent mechanical concerns, 2019 plug-in hybrid models equipped with AeroVironment TurboCord or TurboDock/TurboDX charging systems have capacitors inside those chargers that can fail and create a shock or fire hazard.
On 2018-2020 models, the front wiper arm mounting nuts may not have been tightened properly, which can allow the arms to slip out of position and leave portions of the windshield uncleared. On 2018-2019 models, the front seat rail rear flange nuts may be missing, meaning seats can shift or lose structural integrity in a crash. There is also a tailgate issue on 2018-2019 vehicles: the power tailgate lifting arms can freeze in cold weather and separate from the vehicle, launching a spring rearward with enough force to injure someone standing behind the car.
Going back to the 2013 model year, a defect in the restraint system can cause the seatbelt pretensioner or side curtain airbag to fire without a collision, which can startle the driver and lead to a crash.
The 2012 model has an underbody coating that was applied too heavily on certain vehicles, forming rigid, icicle-like protrusions that can damage the fuel lines underneath and cause a fuel leak.
The 2010 model year carries several concerns. Fuel line rail covers on some vehicles were not properly secured, leaving fuel lines exposed to damage and potential leakage near ignition sources. The curtain airbags on certain 2010 models were assembled incorrectly and may not deploy fully or at all in a crash. The driver's seat side cover panel can disengage the seatbelt anchor from the seat frame in a side impact, leaving the driver without proper restraint. A compliance issue also applies to 2010 vehicles built without a panoramic roof and delivered to Puerto Rico, where interior impact protection does not meet federal standards.
