2021 Volvo XC60

48 complaints on file, page 1 of 3.

1. Filed Sep 23, 2026Failure Aug 1, 2026Glen Head, NYElectrical system

   The air conditioning system in my 2021 Volvo XC60 failed, blowing hot air instead of cold. A Volvo dealer diagnosed the cause as a failed A/C evaporator core and quoted $7,800 to replace it. Volvo Cars North America has declined to provide any goodwill assistance despite this being a widely reported failure across multiple Volvo models (S60, S90, V60, XC60, XC90) at similar mileage/age, and despite Volvo having issued a running design change (a resistor harness, part no. 32241228) intended to prevent the evaporator core from over-cooling and freezing — indicating the manufacturer is aware of the underlying defect. Beyond the loss of cabin cooling, this failure created a separate safety concern: in warm-weather conditions, with the HVAC system unable to properly regulate cabin temperature, the vehicle's infotainment system began to overheat.displayed a thermal-warning message, dimmed/shut down, rebooted, or lost function while driving.] This is a safety issue because the infotainment display controls or is integrated with all functions of the car, and any unexpected shutdown, reboot, or loss of function of this system while the vehicle is in motion is a distraction and a loss of a driver-relied-upon system, particularly on a public roadway. This is also the second time I have experienced an evaporator failure of this type on a Volvo vehicle. My previous vehicle, a 2017 Volvo XC90, suffered an identical A/C evaporator failure on 6/6/2023. Two separate Volvo vehicles failing in the same manner suggests a systemic design or component issue rather than an isolated incident. I am filing this complaint to document the safety impact of this known defect and to request that NHTSA evaluate whether it warrants further investigation.

   NHTSA complaint 11766432
2. Filed Sep 22, 2026Failure May 10, 2026Atlanta, GAVisibility/wiper

   The A/C evaporator core on my 2021 Volvo XC60 suffered a premature structural failure, creating an immediate and severe safety hazard while driving. The component failed precisely five weeks after the Certified Pre-Owned (CPO) warranty wrapper expired. An authorized Volvo dealership service department formally inspected the vehicle and verified an active, heavy refrigerant leak utilizing UV filter video diagnostics. This component defect directly compromises vehicle safety in two distinct ways: Complete Loss of Windshield Defrost Capability: Due to the total failure of the climate control and dehumidification system, the vehicle completely loses its ability to clear the windshield during sudden weather shifts. During a period of heavy rain, the windshield instantly fogged over completely, severely restricting forward visibility and forcing me to immediately pull over on the shoulder to avoid a collision. Toxic Chemical Exposure: The cracked evaporator core continuously vents atomized chemical refrigerant vapor directly into the sealed passenger cabin through the HVAC ductwork. Even with the climate control system and fan completely powered off, a highly concentrated, sharp chemical odor filters into the cabin daily, exposing occupants to toxic chemical fumes while operating the vehicle. Volvo has documented this exact premature failure pattern across its SPA-platform vehicles under Technical Journal TJ 35912, explicitly acknowledging a systemic engineering defect where improper sensor calibration causes the core to freeze, warp, and crack. Despite knowing this part is prone to rapid premature failure, Volvo refuses to issue a safety recall, leaving drivers to operate unsafe vehicles or absorb an exorbitant $3,300+ out-of-pocket invoice to repair a known manufacturing flaw.

   NHTSA complaint 11766267
3. Filed Aug 26, 2026Failure Aug 26, 2026Barker, NYUnknown or other

   Hood latch assembly corrodes making it impossible to open hood or service the vehicle.

   NHTSA complaint 11759733
4. Filed Aug 12, 2026Failure Dec 6, 2025Pleasant Hill, IAElectrical system

   My SUV has a had the check engine light on from a failed battery cell for my 2021 grey Volvo XC60 recharge (VIN [XXX]). I have been without the electric functionality (to charge the hybrid car or use electric power) since mid December and waiting on a warranty part since Dec. 23, 2025. I have been told April 2026 and then August 2026 for this warranty issue that both the dealership and Volvo corporate have agreed is under warranty and needs replaced to make the car functional as intended. They claim the part as been backordered for the entire 8 months. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

   NHTSA complaint 11756600
5. Filed Jul 31, 2026Failure Jul 30, 2026Bethesda, MDUnknown or other

   After backing up out of a parking space, the side mirror on the drivers side moves to an unpredictable position and does not return to its original position. This is potentially dangerous because the driver is not aware of this change in position, and when changing lanes may rely on mirror that is in a faulty position. This appears to be some sort of flaw in the logic that tilts the mirror down when backing up and returns to original position when the car is put back in drive. Regardless of whether I turn this feature on or off, the same malfunction occurs.

   NHTSA complaint 11753923
6. Filed Jul 1, 2026Failure Jun 30, 2026Princeton Jct, NJBlind spot detection, Electronic lock/latch actuator

   The entire right ride of the car just stopped working. Back right door became permanently locked and could not open from outside or inside. When hitting lock/unlock buttons on key fob i) front passenger door would not lock/unlock and ii) right side mirror would not fold in/out. Blind spot monitor and TPMS said they needed service. Left side of car was fine and worked. Car would start normally. I checked all relevant fuses and none were blown. Then all of a sudden it all started working again. My fear is that in the heat of summer what if all doors became locked somehow and i did not have the key fob with the manual key? I have 2 children

   NHTSA complaint 11747588
7. Filed Jun 9, 2026Failure May 29, 2026Kennesaw, GAElectrical system

   An intermittent electrical failure occurred to my wife causing my 2021 Volvo XC60 to stop and then later go into limp mode while driving. The service light went on immediately and was very startling to her and made it difficult for the drivers following as the car speed was significantly reduced/ I suspect limp mode though it was not on the dashboard. When I called Volvo and then brought the car in... it is a known issue to Volvo. They purposively produce a vehicle that is known for sunroof leaks which knowingly leads to electrical issues exposing their customers to harm. Volvo (Geely) inspected the car, found the electrical issues from the front interior to the battery compartment that had water over an inch deep. the VGM (Vehicle Gateway Module) was replaced and reloaded, all connectors were separate/dried and several had to be cut/spliced and rewired due to corrosion damage. Carpets were removed, the gasket was replaced, the front and rear sun roof drains were cleaned out. Aside from the safety concern the shrinking of the rubber gasket caused the issue. Not funny, but Volvo/Geely states that the repair now has a lifetime warranty after I was charged over $4,000 USD. The vehicle is only about 5 years old!!

   NHTSA complaint 11743000
8. Filed May 30, 2026Failure May 11, 2026Mesa, AZFuel/propulsion system

   My 2021 Volvo XC60 experienced a fuel system failure at approximately 53,500 miles. Prior to the failure, the vehicle displayed multiple warning messages and entered reduced-power (limp mode), including the turtle symbol on the instrument cluster. The vehicle unexpectedly would not start despite multiple attempts. The failure occurred while I was at a physical therapy appointment approximately 25 minutes from my home. After approximately 10 minutes, the vehicle started and was able to be driven. Because of the warning messages, limp mode, and failure-to-start condition, the vehicle was taken to a Volvo dealership for diagnosis. The Volvo dealership diagnosed the vehicle with ECM fault code P008A00 (Low Fuel Pressure). According to the repair invoice, testing confirmed that fuel pressure was intermittently low, and the dealership determined that the in-tank fuel pump was faulty. The fuel pump was replaced to correct the condition. This failure created a safety concern because the vehicle became unexpectedly inoperable and would not start when needed. Had the failure occurred in a remote location, during extreme weather conditions, at night, or in an emergency situation, it could have left the vehicle occupants stranded without reliable transportation. The inability to start the vehicle occurred without warning and could have resulted in a more serious safety risk under different circumstances. The issue was reproduced and confirmed by an authorized Volvo dealership, which inspected the vehicle, diagnosed the fault, and replaced the fuel pump. Repair records are available for inspection upon request. The failure occurred at approximately 53,500 miles, which is relatively low mileage for a major fuel system component. Because fuel pump failures can render a vehicle unexpectedly inoperable, I am submitting this complaint for review and investigation.

   NHTSA complaint 11741045
9. Filed Apr 16, 2026Failure Mar 23, 2026Berlin, CTAssist, Steering

   Multiple times, with the Pilot Assist system engaged, the vehicle has pulled me out of my intended travel lane when on a curve, near an on / off ramp, and generally tends to drift from the left to right of the intended lane of travel on straight sections of road. It will drift to the rumble strip and sometimes into the next lane with both hands firmly on the wheel. I find myself fighting the system at these times. When it gets confused, with corners or merges, and on / off ramps, it will abruptly change lanes which is very dangerous. Twice it almost caused an accident. I have had it looked at many times now by Gengras Volvo in East Hartford where I bought the car. I was provided a loaner each time but the car has been in their shop for close to a month over these visits. It happend on one test drive with their repair tech driving the car, so the issue has been verified and recorded by Gengras. Multiple components of the system have been changed out and Volvo has downloaded and reviewed the telemetry twice. Volvo's stance is that the system is functioning correctly, and in times if inclement weather it may not work as intended. Most of my incidents happened on dry roads. Upon researching this on the internet, there are many other owners of Volvos of my year and others complaining of the exact same issues and behavior of the car. I feel it may be a design flaw but in my opinion the system is not safe to use. Volvo went to a completely different system soon after 2021. This was a very expensive option to purchase on the vehicle. We have a similar system in our Acura that works flawlessly on the same roads in any weather condition. I bought this vehicle certified by Volvo with roughly 15K miles for my son to drive when he had just gotten his license as Volvo has an incredible reputation for safely. I do not feel safe with him driving this vehicle as was intended. Latest diagnosis attached, Remainder available from Gengras Volvo, East Hartford CT.

   NHTSA complaint 11731535
10. Filed Apr 10, 2026Failure Apr 8, 2026Holland, MIService brakes

    After 5 times of phantom breaking at high speed I took the car to Betten Volvo. The did a system update to try to correct. The car has now 3 times in 2 weeks again triggered the break at highway speed. I have another appointment scheduled April 21, 2026. Having the brake applied for no reason at this speed is extremely jarring and dangerous.

    NHTSA complaint 11730370
11. Filed Mar 13, 2026Failure Dec 5, 2024Portsmouth, VAExterior

    The driver's side mirror repositions itself downward, upward, or outward when unlocking and opening a door. It infrequently repositions while driving as well. These occurrences put me and others at risk by increasing my blind spot when I need to change lanes. Two Volvo dealers have reproduced the mirror changing positions when unlocking and opening the door, but a few times they were not able to get the car to reproduce it. Technicians have performed software updates, deleted and reprogrammed the keys to the car, and performed a factory reset on the infotainment center to no avail.

    NHTSA complaint 11724198
12. Filed Mar 7, 2026Failure Mar 7, 2026Boca Raton, FLUnknown or otherCrash

    Exiting a parking lot, attempting to break. The plastic break pedal cover fell off and was unable to break in time to avoid a front end accident.

    NHTSA complaint 11722722
13. Filed Jan 8, 2026Failure Nov 28, 2025King George, VAAir bags

    SRS warning light is on

    NHTSA complaint 11709802
14. Filed Dec 29, 2025Failure Sep 26, 2025San Diego, CAElectrical system, Engine, Seat belts

    The USB ports under the center console malfunction frequently. The main, top engine mount disintegrated and needed to be replaced under 50,000 miles. The rear seat seatbelts come loose and sag easily. They do not retract automatically. The rubber stripping, where the door jamb is, comes off. The handles to the air vent break off very easily, rendering the vents inoperable. **The software for the vehicle malfunctions constantly, displaying the incorrect readings for fuel economy, the gas gauge, and more. It is possibly affecting the catalytic converters and O2 sensors. **The vehicle turns itself on, in battery mode. **The blind spot indicators to not light up sometimes and do not make any noise indications of nearby cars.

    NHTSA complaint 11707518
15. Filed Dec 16, 2025Failure Dec 13, 2025Middletown, CTPower train

    Serpentine belt failure at 70K miles. Was driving back home when I felt the traction misbehaving and the check engine light came on. Was able to get home safely and brought the car to the garage the next open day. During inspection, serpentine belt was found missing 1 rib and was caught in splash fan. Had to pay almost $1000 to replace it as insurance had run out a couple months prior. Volvo tech said it was almost surely a defect in the belt as these last typically ~150k miles and they had seen other such recent cases of early failure. I was not happy having to pay to replace a defective part which moreover was about to catastrophically fail, destroying my engine/traction and potentially hurting me. Thankfully the check engine light, which was apparently unrelated (oxygen sensor which needed to be replaced for another $1000) brought me to the garage before the accident happened.

    NHTSA complaint 11705446
16. Filed Sep 22, 2025Failure Sep 15, 202545,000 milesPedricktown, NJSteering

    The contact owns a 2021 Volvo XC60. The contact stated that while driving at undisclosed speeds and turning, the front end of the vehicle made an abnormal grinding sound. Additionally, the contact stated that the steering wheel seized after turning, which required the contact to jam the steering wheel for the steering wheel to return to the center. There was no warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed and determined that the steering rack had failed internally and needed to be replaced. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 23V001000 (Steering); however, the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was approximately 45,000.

    NHTSA complaint 11688891
17. Filed Sep 8, 2025Failure Dec 2, 2024Temecula, CAWarnings, Rearview system braking, Electrical system

    My car was backed into July 4, 2024, unoccupied and had damage done to the hood and front light and bumper. The person who hit the car had insurance and I took it to a local collison company for the repairs In November 2024. (Insured would not return calls to insurance company so it took this long for repairs) I began taking it to Volvo OC in December because the sensors were constantly lighting up and beeping constantly with no one around me. I took it to Volvo many times from December to August 2025. They would have my car for a week or two and think they fixed it and it was not fixed. After Volvo sent me a note saying that Corporate was not going to pay to do anything and they were done with trying to fix the car I took it back to my collison company. When Volvo last had it they told me that the wiring harness was not the correct part number and that the collision company installed the wrong one. I called them back and they explained that they had to call Volvo Mission Viejo and gave them the VIN number and they installed what was sent. I took it back to the collision company and they called and ordered another harness and they received the exact same harness. They installed that one and the sensors still do not work correctly. They then called Volvo Mission Viego again and they were told there was a cable that was needed if a car was in an accident and 2 sensors needed to be attached to the cable and the other sensors to the harness. So they did that. And still the same issue. At that time Volvo told me that the sensors in my car were not the correct sensors and that they were not the sensors that came with the car. The collision company said they removed the sensors from the harness but attached the exact same sensors during the repair. So both Volvo and the collision company have left me hanging and this is a safety issue. If I am looking one way for traffic and the beeping goes off it is startling to think someone is coming from the other

    NHTSA complaint 11685673
18. Filed Sep 1, 2025Failure Aug 1, 2021Sammamish, WAFuel/propulsion system, Service brakes, Steering

    Rotor seems to have worn out much quicker than expected. When I break, I can feel certain vibration / bumps. When breaking while going down on a hill, front break also has made screeching noise. Steering feels stiff at times. generally, I have always been topping up gas more than the advertised mileage performance / EPA

    NHTSA complaint 11684241
19. Filed Dec 28, 2024Failure Dec 27, 2024Riverview, FLSeat belts

    Rear Center Seat seatbelt buckle does not latch.

    NHTSA complaint 11632886
20. Filed Dec 16, 2024Failure Nov 29, 2024Baltimore, MDLatch

    The passenger side rear door locked and could not be open from either the inside or the outside. The dealer concluded that the door lock failed in the locked position. It gained entry to the door panel with the door shut, removed the old lock, opened the door, installed a new lock assembly and reassembled the door. Because the car was slightly out of warranty, we had to pay for the repair. Until this was done, we felt very unsafe. In the event of an accident or emergency, the passenger on that side of the car would not be able to exit the car. There was no warning prior to this happening. It just stopped working.

    NHTSA complaint 11631036