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2025 Volvo Ex90 Recalls, Issues & Maintenance

The 2025 Volvo Ex90 carries 3 open NHTSA recalls — most recently covering critical fasteners and concealment devices. Owners report 6 recurring issue clusters, led by “Onboard charger (GHCA) AC charging failure.” Volvo schedules maintenance every 10,000 miles or 12 months, whichever comes first — the cluster's service reminder counts down to it. Drive-E four-cylinder engines (2015+) require Volvo-spec 0W-20; the older five-cylinder turbos (XC70, C30) run on a timing belt with a firm replacement interval, not a chain. AWD Volvos use a Haldex-style rear coupling whose fluid service is the difference between an AWD system that lasts and a four-figure pump-and-clutch repair.

3 Open Recalls

Source: NHTSA

SEATS:CRITICAL FASTENERS

Campaign #24V869000 · Nov 19, 2024

Issue: Volvo Car USA, LLC (Volvo Car) is recalling certain 2025 EX90 vehicles. The bolts for the second-row free-standing seat may not be tightened properly.

Risk: An improperly tightened seat may not adequately restrain the occupant during a crash, increasing their risk of injury.

Fix: Dealers will inspect and tighten the bolts as necessary, free of charge. Owner notification letters were mailed January 10, 2025. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10292.

EXTERIOR LIGHTING:HEADLIGHTS:CONCEALMENT DEVICES

Campaign #25V071000 · Jul 2, 2025

Issue: Volvo Car USA, LLC (Volvo) is recalling certain 2025 EX90 vehicles. Due to a software error in the low power controller (LPC), the headlight shutters may close over the high and low beams while driving.

Risk: A loss of headlight function while driving can reduce visibility and increase the risk of a crash.

Fix: The LPC software will be updated manually, free of charge. Owner notification letters were mailed March 12, 2025. Owners may contact Volvo's customer service at 1-800-458-1552. Volvo's number for this recall is R10298.

STRUCTURE:BODY:HATCHBACK/LIFTGATE:SUPPORT DEVICE/STRUT

Campaign #25V654000 · Sep 30, 2025

Issue: Volvo Car USA, LLC (Volvo) is recalling certain 2025 EX90 vehicles. A spindle nut may detach from the Power Operated Tailgate (POT) drive units, causing the tailgate to suddenly drop.

Risk: A tailgate that suddenly drops can hit a person, increasing the risk of injury.

Fix: Owners are advised not to use the POT function until the repair is completed. Dealers will replace both POT drive units. Owner letters were mailed November 24, 2025. Owners may contact Volvo's customer service at 1-800-458-1552. Volvo's number for this recall is R10342. Vehicle Identification Numbers (VINs) involved in this recall will be searchable on NHTSA.gov beginning October 7, 2025.

Recall data refreshed Sep 13, 2026.

Known issues for this vehicle

What drivers and federal regulators have officially reported about the 2025 Volvo Ex90.

Reported to NHTSA

Onboard charger (GHCA) AC charging failure

ELECTRICAL SYSTEM, FUEL/PROPULSION SYSTEM

16 NHTSA complaints · 2025-02 → 2026-03

“The Grid to High Voltage Converter A (GHCA) is a critical, often failing, component in 2025+ Volvo EX90 and Polestar 3 electric vehicles that converts AC grid power to high-voltage DC for the battery has failed 5 times in my car with no fix from Volvo in the foreseeable future”
— Owner report, NHTSA ODI #11715615
“On Saturday 6th December, I unplugged the car from the A/C charger after it had finished charging to 90% in my garage and there was a very loud bang heard from under the car”
— Owner report, NHTSA ODI #11708444
“I have been in multiple situation where my car is unable to charge from my home charger, and the issue is always same which is the need of GHCA replacement. Right now, GHCA for EX90 is in national back order with unknown ETA”
— Owner report, NHTSA ODI #11709750

Read all complaints on NHTSA →

One-pedal drive deactivation without warning

SERVICE BRAKES

4 NHTSA complaints · 2025-07 → 2026-06

“The One Pedal Drive function (regenerative braking) intermittently deactivates without warning after startup”
— Owner report, NHTSA ODI #11741767
“One pedal driving randomly turns off when starting the vehicle”
— Owner report, NHTSA ODI #11678075
“The one-pedal drive feature automatically switches off, even though it is saved in my profile”
— Owner report, NHTSA ODI #11691768

Read all complaints on NHTSA →

Instrument display blackout while driving

ELECTRICAL SYSTEM, UNKNOWN OR OTHER, LANE DEPARTURE

6 NHTSA complaints · 2025-01 → 2026-06

“While driving on the highway, the entire digital instrument cluster and infotainment screen went completely black without warning”
— Owner report, NHTSA ODI #11651941
“The vehicle supports a feature to reset the display computer by holding the play/pause button for approximately 45 seconds”
— Owner report, NHTSA ODI #11693256
“When I came back out to the car and opened the door, the display behind the steering wheel stated "System communication fault. Pilot Assist deactivated. Find a place to stop and select P to park”
— Owner report, NHTSA ODI #11634197

Read all complaints on NHTSA →

Driver support system fault disabling ADAS features

STEERING, LANE DEPARTURE

6 NHTSA complaints · 2025-01 → 2026-06

“When leaving a downtown parking garage, I noted the following alert on the driver's screen: "Steering fault - Drive with caution. Book a service."”
— Owner report, NHTSA ODI #11698396
“While driving, my car suddenly displayed the "Driver Support System Fault" icon (Picture 1)”
— Owner report, NHTSA ODI #11693995
“Multiple times I have gotten a "Park assistance fault - book a service" message while driving and the parking sensors stop working”
— Owner report, NHTSA ODI #11741674

Read all complaints on NHTSA →

Critical fault warning with loss of power while driving

ELECTRICAL SYSTEM, FUEL/PROPULSION SYSTEM

7 NHTSA complaints · 2025-05 → 2026-07

“I am writing to file a formal safety complaint regarding my Volvo EX90, which experienced a complete and dangerous shutdown while driving on a LA freeway on Christmas Day”
— Owner report, NHTSA ODI #11711504
“While driving on I-5 north by Castaic (exit 176A) the car displayed "electric system temporarily limited" then "critical electric fault" at which time it rapidly decelerated while on the freeway”
— Owner report, NHTSA ODI #11710154
“When I applied the brakes they did not respond. I came to a stop only when the car lost momentum”
— Owner report, NHTSA ODI #11704750

Read all complaints on NHTSA →

Unintended acceleration without driver input

VEHICLE SPEED CONTROL

6 NHTSA complaints · 2025-10 → 2026-08

“I was parked in a parking lot and when I released my foot from the break, the car accelerated on its own and crashed into the car in front of me”
— Owner report, NHTSA ODI #11756276
“On multiple occasions, immediately upon shifting the vehicle into Drive — before I touched the accelerator pedal — the vehicle accelerated forward on its own without any input from me”
— Owner report, NHTSA ODI #11746581
“After finishing, when I released the brake pedal to leave, the vehicle suddenly accelerated forward on its own, much faster than normal creeping speed”
— Owner report, NHTSA ODI #11692870

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 13, 2026. Investigation data refreshed Sep 13, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter (Annual Service)

Every 10,000 mi

Replace every 10,000 miles or 12 months with Volvo-spec oil (VCC 0W-20 on Drive-E engines). Turbo five-cylinders in the older XC70/C30 are harder on oil — many specialists suggest 7,500 miles on those.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Timing Belt (5-Cylinder — XC70, C30)

Every 105,000 mi

Volvo's five-cylinder engines use a timing belt: replace around 105,000 miles or 10 years (verify your year's exact interval). Interference engine — do the tensioner and idlers in the same job. Drive-E four-cylinders (2015+) use a chain instead.

Estimated cost — typical U.S. ranges

Dealer

~$935–$1175

Shop

~$655–$825

DIY

Pro only

On interference engines, a snapped belt destroys valves. Worth doing on schedule. Bundle water pump + tensioner — labor is already there.

Tire Rotation

Every 10,000 mi

Rotate at every annual service. AWD models: replace tires in matched sets — tread mismatch works the Haldex coupling constantly.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect pads, rotors, and hoses at every service. Heavy XC90s wear front pads quickly in city duty; check electronic parking-brake function on 2016+ models.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 24,000 mi

Replace DOT 4 fluid every 2 years regardless of miles — standard practice for the moisture-absorbing fluid, and cheap insurance for the ABS unit.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

AWD Coupling Fluid (Haldex)

Every 40,000 mi

AWD models: replace the rear coupling's fluid roughly every 40,000 miles (Volvo's published interval varies by generation — check your manual). Skipping it clogs the pump filter and kills the AWD unit; whirring from the rear axle is the classic late symptom.

Estimated cost — typical U.S. ranges

Dealer

~$220–$290

Shop

~$155–$205

DIY

~$40–$90

VW/Audi/Volvo AWD coupling — specific fluid required. Filter usually swapped at the same time.

Automatic Transmission Fluid

Every 60,000 mi

The Aisin 8-speed is labeled long-life, but Volvo specialists broadly recommend fluid service around 60,000 miles — sooner with towing. Use the specified JWS/Toyota WS-type fluid for your gearbox.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Spark Plugs

Every 60,000 mi

Drive-E turbo fours: plugs around every 60,000 miles. Supercharged+turbocharged T6/T8 engines run higher cylinder pressures — don't stretch the interval.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Air Filter

Every 30,000 mi

Replace roughly every 30,000 miles; inspect annually in dusty climates.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 10,000 mi

Volvo specifies frequent cabin-filter replacement — annually on most models, in keeping with the brand's air-quality focus (CleanZone on newer cars).

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Engine Coolant

On condition / lifetime

Volvo long-life coolant typically runs ~10 years on the schedule; refresh with Volvo-spec coolant around 100,000 miles per independent-specialist practice.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2025 Volvo Ex90 reflects Volvo's published service intervals and the Volvo Service Reminder system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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