Volvo Xc90 Recalls

The Volvo XC90 has 53 recalls spanning the 2003 through 2025 model years, with the most serious recent issue being a steering gear defect on 2019–2022 models where a misassembled screw can fall into the gearbox housing and cause the steering wheel to lock up without warning.

The 2022–2025 model years carry several notable issues. A software error on 2022 plug-in hybrid models can cause a complete loss of braking. On 2022–2023 vehicles, a software fault in the engine control module can prevent the combustion engine from starting, draining the high-voltage battery and leaving the car without drive power. The 2023 model year has a separate brake control module diagnostic error that can disable anti-lock brakes, stability control, and traction control simultaneously. Also on 2023 models, a false warning can mask a real failure in the emergency call system, potentially delaying help after a crash. The rearview camera on 2023–2025 models can fail to display when the vehicle is shifted into reverse.

The 2020–2022 years have a high-voltage battery recall affecting plug-in hybrid models where a short circuit inside the battery pack can start a fire even when the vehicle is parked and off. On 2020–2021 vehicles, an improperly welded rotor and shaft inside the integrated brake system can separate, reducing braking assistance and disabling anti-lock brakes and stability control. The 2021 model year has a separately filed issue where the airbag and restraint system control unit may not be properly secured to the body, potentially causing it to detach in a crash and prevent airbags, seatbelt pretensioners, and the high-voltage battery disconnect from functioning. Also on 2021 models, seat belt automatic locking retractors can deactivate early, preventing child restraint seats from securing properly.

The 2015–2024 model years share a recall where second-row seat belt buckle and anchor bolts may not be tightened properly, allowing the belt to fail in a crash. The 2019–2020 years have two additional issues: a low-pressure fuel pump that can blow a fuse and stall the engine, and an automatic emergency braking system that may not detect obstacles due to a software and hardware incompatibility. On 2017 models, the inflatable curtain airbag mounting bolts can break and cause improper deployment in a crash, and a seatbelt retractor component in the third-row right-side position can detach after deployment and become a projectile inside the cabin.

The 2016–2017 model years have a cluster of safety system concerns. An air conditioning drain hose installed incorrectly can leak water into the cabin over time and interfere with airbag deployment. The front passenger seatbelt buckle stud can loosen and separate from its bracket. On 2016 models specifically, the third-row curtain airbag can fail to fully inflate, front seat side-impact airbag wiring may be routed incorrectly and become damaged, and a D-pillar trim panel can block the curtain airbag from inflating for third-row passengers. The 2016 model also has a coolant bleeder hose that can crack and leak coolant onto the exhaust or into the catalytic converter heat shield, creating a fire risk when the vehicle is stationary. On 2016–2020 Excellence trim models, moisture on the rear seat touchscreen can send the front passenger seat all the way rearward