According to media reports, Volvo Cars has issued a large-scale recall in the U.S. market involving 14,014 electric and plug-in hybrid vehicles. The recall stems from a serious software defect that may cause the vehicle to completely lose braking capability under specific driving conditions.
Investigations reveal that the issue primarily affects certain models from the 2020 to 2026 model years equipped with software version 3.5.14. When a driver operates the vehicle in "B" mode (for plug-in hybrids) or one-pedal drive mode (for pure EVs), and drives downhill continuously for over 100 seconds without pressing any pedals, the brake system may completely fail. This malfunction not only compromises the brake control module and overall driving performance but also poses a significant threat to the core user experience of electric vehicles.
The affected models include:
2023 C40 Recharge (pure electric)
2025 EC40
2023–2024 XC40 Recharge
2020–2026 XC90 Recharge (plug-in hybrid)
2022–2026 XC60 Recharge
2023–2025 S60 Recharge
2024–2025 V60 Recharge
2025–2026 EX40
2025 S90 Recharge
Notably, the software defect is limited to specific versions installed by dealers and was not distributed via over-the-air (OTA) updates.
Volvo has released a corrected software version 3.6.4, which began rolling out via OTA and dealership channels starting June 16. A company spokesperson emphasized: "We recommend that owners who have not yet installed the update avoid using 'B' mode or one-pedal driving while operating their vehicles."
The U.S. National Highway Traffic Safety Administration (NHTSA) published the recall notice on its website, stating that the brake module software will be updated free of charge via OTA or at dealerships. Owner notification letters are expected to be mailed by August 6, 2025.
The defective 3.5.14 software version was released in April this year and also included updates for lane keeping assist, tire pressure monitoring, and traffic sign recognition. However, Volvo has not yet provided a detailed explanation on how this critical brake failure passed internal safety checks.
This is Volvo's second major recall of the year. Earlier, approximately 7,500 plug-in hybrid vehicles from model years 2020 to 2022 were recalled due to a risk of battery-related fires.
After experiencing a decline in sales during Q1 2025, Volvo underwent a leadership change in April. Former CEO Håkan Samuelsson returned to the role after Jim Rowan's departure. Despite record-breaking EV sales in 2024 and the brand's ambitious electrification goals, Volvo has faced slower growth in 2025, with increasing pressure from quality issues and shifting consumer preferences.
