What 47 owners told NHTSA about the 2018 Volvo XC90 T5

The air conditioning evaporator core has been widely known to freeze and crack on 2016-2021 models of the xc90 which sends toxic refrigerant smell thru the vents. This is a big safety hazard and should be recalled. Volvo knows about this but only does a goodwill repair to loyal customers who purchased the vehicle new and have all service records from the dealership. This is a $4000 repair for everyone else for a manufacturer defect and safety issue

NHTSA ODI 11749955

VIN: [XXX] •Make/Model/Year: 2018 Volvo XC90 •Mileage at time of each incident (58,385 / 58,480 / 68,261) •Approximate dates of each incident Vehicle has experienced recurring brake system failures. First, a seized rear brake caliper (Sept 2025) requiring caliper/rotor/pad replacement. Four days later, brake pedal became stiff and hard to depress; brake booster diagnosed as internally failed and replaced. Approximately 9 months and 9,800 miles later, vehicle experienced complete loss of braking ability while driving — brake pedal would not stop the vehicle, driver had to use the parking brake to stop, vehicle was towed to dealer. All repairs performed at authorized Volvo dealer. This is a repeat failure of the same brake system after a documented repair. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11748675

I am reporting a serious safety concern involving a 2018 Volvo XC90 T8 PHEV. On [XXX], at approximately [XXX] CT, the vehicle experienced a sudden multi-system safety and actual brake failure while in a parking-lot/low-speed setting near [XXX} in Austin, Texas. The vehicle displayed multiple urgent warning messages and indicators, including power steering failure / stop safely, brake/ABS warning, SRS airbag service urgent warning, stability/traction warning, battery/electrical warning, check-engine warning, and tire-pressure warning. The vehicle ended in an irregular/distressed parking position after trying to locate a concrete block to force stop the car due to ABSOLUTE BRAKE FAILURE, E BRAKE SEEMED TO NOT WORK EITHER. The concern is not simply that a warning light appeared. The event involved steering, braking, airbag/SRS, stability, and electrical warnings at the same time, making the vehicle unsafe to operate AND SOMEHOW THE BRAKES WEREN’T OPERATING DUE TO THE LACK OF FUNCITONING. Photos were taken of the warning messages and vehicle position. Prior related history:
This vehicle has prior safety-system history involving SRS Airbag Service Urgent warnings and braking/vehicle malfunction and movement concerns. Earlier review and discussion involved Volvo engineering, VDDM replacement, CAN/network concerns, calibration requirements, voltage/12V battery considerations, software/module updates, and post-repair validation. The VDDM is understood to participate in vehicle dynamics, stability control, brake coordination, and PHEV regenerative/hydraulic brake interaction. Prior documentation also raised concern that intermittent brake, SRS, VDDM, CAN, and calibration issues may not reproduce during a short dealer test drive. Safety risk:
The safety risk is that the vehicle may experience sudden or intermittent loss, degradation, or warning of systems involved in steering, braking, stability control, and airbag readiness. A simultaneous power steeri INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11746058

At approximately 6:30 PM, after normal driving and parking at a local park, our family was unloading children from the vehicle. One child was standing next to the vehicle while we removed a younger child from the rear seat. The child suddenly screamed and stated that he had burned himself. We later determined that he had accidentally come into contact with the exterior exhaust outlet. As we continued walking, we noticed the injury was more severe than initially believed. We took photographs of the burn and later sought medical evaluation. The physician determined that the injury was a second-degree burn due to blistering and provided treatment recommendations. The vehicle was operating normally, and there were no warning lights, messages, or signs of a malfunction before the incident. The concern is that the exposed exhaust outlet becomes hot enough during normal vehicle operation to cause a serious burn from brief accidental contact. We believe the location and accessibility of the exhaust outlet may present a burn hazard, especially to children during routine loading and unloading activities around the vehicle. The vehicle and photographs are available for inspection. The vehicle has not yet been inspected by the manufacturer or a dealer regarding this incident.

NHTSA ODI 11744366

My 2018 Volvo XC90 T8 Plug-In Hybrid experienced a catastrophic, premature component failure of the Electric Rear Axle Drive (ERAD) propulsion system while driving. The ERAD unit suffered a total failure of internal bearings and sensors, completely disabling the electric rear wheel propulsion system and suddenly forcing the vehicle into a reduced-power "limp mode" on the road. This sudden loss of hybrid propulsion creates an immediate highway safety hazard, removing expected acceleration and vehicle control in traffic. Volvo has documented this exact engineering flaw internally under Technical Journal TJ 36665, recognizing a manufacturing vulnerability in these specific hybrid components. However, the manufacturer is refusing to provide remedy or financial cost-sharing to repair this vital propulsion and safety defect, leaving a hazardous, compromised vehicle on the road.

NHTSA ODI 11744495

My Volvo's XC90 brakes have failed twice. At around 95,000 miles, my brakes stopped working, and then I had them repair it. They charged me close to $3,500, which they said they were able to cover under warranty, and I only had to pay the deductible, which I don't remember. In less than nine months, at about 104,000 miles, the same problem persists. Both times I was driving the car, by God's grace and luckily, I was under 10 mph. I literally parked and started driving after that, and I realized the brakes weren't working again. I'm just thankful to the Almighty that I was not at 55 or 60 mph on a freeway when the brake stopped working.

NHTSA ODI 11731985

2018 Volvo XC90, VIN [XXX] , 54,618 miles. Original owner. All service performed exclusively at Volvo Cars West Houston (same dealer, all three failures). Volvo Technical Journal TJ 34648.1.2, titled "Prior Approval - Lack of airflow causing poor cabin cooling," is classified as a Product Fix and explicitly lists the 2018 XC90 as an affected vehicle. This TJ required the dealer to submit a Prior Approval report to Volvo Corporate when installing the resistor fix. At 12,017 miles (August 2020), the dealer installed the evaporator resistor per TJ 34648.1.2, Part No. 32241228, under VST Operation 98734-2 — meaning Volvo Corporate has documentation of this vehicle's evaporator vulnerability on file since 2020. At 15,930 miles (March 2021), the AC compressor failed and was replaced under warranty, consistent with refrigerant starvation from the same underlying evaporator leak. The evaporator has now failed completely at 54,618 miles despite Volvo's own corrective measure being applied at 12,017 miles. The current failure (April 2026) includes a confirmed front evaporator refrigerant leak and AC discharge hose leak, documented by dealer borescope inspection showing corrosion on the evaporator fins and visual evidence of refrigerant oil residue at the discharge hose fitting. Dealer repair estimate is $4,406. This is a documented pattern failure across 2016-2018 Volvo XC90 models. Volvo Cars USA was contacted for goodwill assistance and denied the request within 24 hours without meaningful review. Case number [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11730540

2ND row, center seat, seatbelt lock will not work, will not latch/lock, cannot use seatbelt. Since owning car, the seatbelt locked intermittently, as of today, it does not work at all.

NHTSA ODI 11720776

Rear Drivers door (left) fails to latch. Volvo has an updated part for better water ingress prevention, then the part that was used to build the car. The problem is that water enters the moveable window, runs down the metal channel separation gthe fixed and moveable window, and enters the door latch mechanism. This is extremely dangerous, in that the door may appear closed, and the vehicle may allow the driver to move forward or backward, but the door is not latched and can fly open leading to death! This is an issue known by Volvo, hence the updated OEM replacement part, however they are grossly negligent in not reporting or self recalling vehicles for this issue.

NHTSA ODI 11715235

At random times the back doors will not open, from the inside or outside…hit all the unlock buttons and will NOT open. If this is not a massive safety issue, I don’t know what is…. If we get in a wreck and our car is on fire and we cannot instantly get ourselves or our children out quickly that’s a problem… if we wreck on the freeway and we see vehicles coming at us and we cannot quickly exit. This is a problem. For a car company to not address this it is gross negligence… we own a Ford focus it’s been taken in about three times for door recalls, but we never even actually had an issue…Volvo being a luxury car company and choosing to ignore this issue at the expense of the consumer has went on too long! This hasn’t happened only once, has happened sporadically multiple times

NHTSA ODI 11711121

My car completely locked up on the road and came to a screeching stop. This car is known for having the ERAD completely fail and it could have caused it to have a serious accident. It has also caused my car to plummet in value losing over 30k in just 3 years. Now my repairs cost nearly what it’s worth and aren’t guaranteed to actually fix it. It’s terrible. I’m so upside down n my loan due to this issue that they dealerships refuse to help on. The dealership acknowledges it is a design flaw but yet they won’t help. I have an email stating that it is a design flaw

NHTSA ODI 11691437

On 8/20/2025, my 2018 Volvo XC90 T8 suffered catastrophic failure of the Electric Rear Axle Drive (ERAD). The vehicle suddenly developed a loud whining noise from the rear and became undriveable. This ERAD had previously been replaced under warranty at Boston Volvo Cars. On 10/28/2025, Queens Volvo inspected the vehicle and confirmed the failure was caused by improper prior service. Their technician documented that the ERAD housing was likely not properly torqued, which led to transmission fluid leaking over time, sludge buildup, and internal damage to gears and motor. The failure was sudden, confirmed by an authorized Volvo dealer, and the ERAD is no longer serviceable. This created a safety risk by causing immediate loss of propulsion and stability. If it had occurred at highway speeds, the risk of crash would have been significant. The failed component remains available for inspection.

NHTSA ODI 11688273

3 weeks ago we had the transmission module fail on our vehicle while it was being driven. According to Volvo forums, this is a multi-model year, multi vehicle issue for those with sunroofs. Accrding to the dealer in our case, the seal failed, and water runs into the compartment where the transmission module is located, causing it to fail. We had it happen twice, and both times on the highway, with the engine running ragged causing it ot accelerate and then quickly decelerate. There were 3 warnings that popped up-"Gear lever locked," "transmission acceleration performance reduced," and "Parking Brake unaavialble." It happened twice and and was towed to the dealer both times, as it was not drivable-once the vehicle was parked it would no longer move out of park. The first time the diagnosis and module reset was comped by the dealer (Borton Volvo, Golden Valley, MN) and the second time, the transmission module was "dried out," and the sunroof seal was replaced, which was just under $700. It is available to be inspected if necessary. The vehicle was a hazard to others on the road while it was "acting up." Dealer was familia with the issue. No inspection was done other than by the dealer Warning lamps as outlined above

NHTSA ODI 11676768

The contact owns a 2018 Volvo XC90. The contact stated that the A/C unit failed to operate as needed, causing the HVAC system to become inoperable. The vehicle was taken to a dealer where a diagnostic test was performed, which showed that the evaporator core inside the HVAC system was cracked and needed to be replaced. The contact attempted to have the part replaced; however, the contact was informed that the part was on backorder. The vehicle was not repaired. The manufacturer was notified of the failure but offered no assistance. The failure mileage was 100,000.

NHTSA ODI 11663103

While actively driving into an intersection, driving on the street and or stopped at a light or at a stop the vehicle will shut off, the lights on the dashboard will sometimes be on, other times go completely black, a notification pops up on the dashboard saying "engine not in P". There is no way I'm aware of to re create this action. My children's safety as well as mine has been put at significant risk and in harms way as well as others due to the severity and nature of this unexpected risk while driving on the freeway, through intersections and in general driving through traffic and busy streets. I've had multiple close calls of almost being hit when the car stopped while I'm driving with my children. The problem has yet to be reproduced by the dealer at this time however we have photos and video of it's ongoing safety concern. It has not been inspected by the manufacturer nor police but is currently at the dealer undergoing inspection. There has not been any notifications or warnings prior to any one of these serious events, the message only comes up when the car is off and won't go.

NHTSA ODI 11657576

The engine coolant bleeder hose in my 2018 Volvo XC90 cracked in the middle of my journey causing a severe coolant leak. This happened in August of 2024 while driving and the engine coolant suddenly started showed warning with low level and the engine started overheating. The vehicle would not accelerate past 20 mph, and the temperature warning light flashed continuously, creating a safety hazard in traffic. The Volvo dealership diagnosed the issue and confirmed that the coolant bleeder on the supercharger is broken and leaking. They replaced the bleeder hose and vacuum fill system. I believe similar issues happened to the 2016 models and a recall was issued for the coolant bleeder hose (part # 32249907-0) to be replaced by Volvo. This has not been recalled for the 2018 models, making it an expensive replacement for me. I urge NHTSA to investigate Volvo XC90 coolant hoses for material defects, as this issue endangers drivers through unexpected breakdowns and engine failure.

NHTSA ODI 11655729

The vehicle engine will fail while driving. The electronics reflect the vehicle is still running. Restarting is not immediate and is difficult. This is a known problem that Volvo recalled for 2019/2020 XC90s. Volvo will not diagnose and repair under goodwill despite my repeated attempts.

NHTSA ODI 11655417

The first incidence occurred around [XXX]. I was traveling [XXX] on [XXX] in North Carolina about an hour north of Charlotte. I pulled into a rest area and, upon pressing the brake pedal, heard a bit of a hissing noise and suddenly the brake pedal was extremely hard and the car was very difficult to bring to a stop. I did an online search for what might be wrong and discovered it was likely a brake booster failure. I drove the car onto Charlotte, carefully and with extreme difficulty, and took it to the Swedish Connection, a local Volvo specialist. They confirm the diagnosis and replaced the brake booster. Last night, [XXX], I drove the car down to Pickens South Carolina for work. When I got in to return to Charlotte late at night, I turned the ignition, put the car in reverse, and, with my foot on the brake and waiting to back out of the parking space, I heard that hissing noise again. Sure enough, the brake booster had evidently failed again. I drove the car back to Charlotte, mostly on [XXX], and the electronic braking seemed to work OK under cruise control maintaining speed and distance between other cars in traffic. Of course, driving the vehicle on local roads, through stoplights, and turns was extremely difficult and dangerous. I have returned the car to the same mechanic that repaired the last brake booster. I will be reporting this to Volvo as well, as this is a serious safety issue and defect with my vehicle. The mechanic has confirmed that this has happened in other Volvo XC 90s. The vehicle has NOT been inspected by the manufacturer. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11654773

My 2018 Volvo XC90 had repeated water leakage from the panoramic sunroof. In most cases, when the vehicle is parked flat or the front is at a slight angle, water leaks in and collects in the cargo area. It collects into a plastic compartment over the battery located on the right side of the cargo area and/or on top of the rear cargo mat. When the vehicle is moving and it is raining, water leaks in from the rearview mirror, making the entire dash, screen, shifter and both driver and passenger wet. The rain also comes in from the rear right side of the second row making the entire seat or any passenger sitting there wet. Volvo is not acknowledging this defect nor are there any solutions in place. This is extremely concerning.

NHTSA ODI 11631071

Door handle for drivers side door breaks off into hand. Exiting vehicle made extremely complicated: if window is compromised in any way or lock system is compromised in any way, exit of vehicle is impossible.

NHTSA ODI 11622921

This morning and a few days ago, ice cold water was dripping onto my control display pad and on me. The leakage came from the ourside down the plastic compartment behind my rearview mirror. This was distracting while I was driving since there was now water on me, and it was shorting out and affecting my control display. It would continue to be buggy while driving. I believe this issue is a result from a cracked seal between the windshield and the car body. I have seen other documented cases on volvo forums.

NHTSA ODI 11602688

Rear passenger door handle inoperable from both inside and outside the car. A quick google search shows this is a common, well known issue in all 2016 - 2024 and beyond Volvo XC90s. Concerning is this prevents egress from the vehicle in case of emergency. Confirmed issue exists while car is unlocked and child locks deactivated as can be seen in video. Rear driver door works as appropriately, rear passenger fails to open. No warning lights or codes. Issue first appeared 7/10/2024 and persists. Door cannot be opened. Videos available upon request.

NHTSA ODI 11601082

On Monday [XXX] I started my car and immediately a warning signal on the dashboard read ENGINE LOW Performance , and the dashboard went black and the engine cut off. The car was then towed to the Glen Cove Volvo. After a diagnostic I was informed the following needed to be replaced - FUEL FILLER PIPE 2) FUEL PRESSURE LOW FUEL indicator 3) the aforementioned replacements will require calibrated software update. . I bought this car brand new and I am the only owner and it has only been serviced by Volvo. This car ONLY has 59, 300 miles. I researched the problem online and noted it was a common problem with the. same make and year of my car and could not understand why there is not a recall for my car, by Volvo for this issue no matter the mileage. I came across correspondence on the internet from [XXX] referencing service action S29843 - fuel tank filler pipe insert was manufactured out of specification for ONLY T8 engines. I reached out to Volvo Car USA customer care and inquired about them covering the cost of the repairs and also informing them that this problem is not only affecting T8 engines. I just received a response for my concern stating THEY ARE SORRY THEY CAN NOT ASSIST ME WITH THIS MATTER. I cannot begin to express how sadden and disappointed in the corporation, to experience their lack of compassion and. concern about their product after I spent thousands of dollars of my hard earned money on this defective car. I have no faith in Volvo and no longer feel safe driving this car. I will tell all my relatives and friends of my experience to save them from Volvo's lack of concern about their CUSTOMERS' safety. This is clearly no wear and tear. There are multiple posts on the internet. There's a case of replacement at 10,000 miles, another case where it was replaced and failed again and the dealer is requesting the owner to pay. This this not right. There should be a recall for the entire system when it fails.-clearly defective INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI 11587090

Chrome plated trim peels away from the surface on middle console and exterior door handles and is extremely sharp causing deep cuts, seems to be a common and known issue but Volvo will not repairs or address the issue.

NHTSA ODI 11555413

Wipers began to turn on randomly without driver command causing distractions in a vehicle with 38,000 miles. There is a technical service bulletin about this issue (32366). It is known that the wipers will completely fail to work after an unknown, but rather short interval. Failed windshield wipers would render the vehicle unsafe to operate, therefore we elected for Immediate repair. The repair was in excess of $1,500 and the manufacturer refused to pay for the repair out of warranty.

NHTSA ODI 11549503