Fault File
All models / All cars / Family & large SUVs / Volvo XC60

Volvo XC60

All generations and engines together · 112,169 MOT tests in the 2025 data · typical mileage at age 7: 71k

First-time failure at age 7
16.9%
Across 12,021 tests. The average across all tracked models is 19.5%.
Rank at age 7
91 of 239
1 = lowest failure rate among the models tracked.
Typical mileage at age 7
71k miles
Check the mileage view below; low-mileage models can look better by age than they are.

Generation

Split by first-registration year. Cars registered in a changeover year can belong to either generation.

How this model wears

Volvo XC60Class average, all tracked models

Known issues

Measured

Computed from DVSA MOT results, all of Great Britain, 2025. Nothing here is opinion.

What testers flag

Share of tests where each item was recorded. The dark tick is the class average across all tracked models; bars are scaled within each group.

Faults with the car itself

The rows that judge the model rather than its keeper. 51,410 tests in this band.

A suspension pin, bush or joint excessively worn
Advisory
8.4%class 7.0%
A spring or spring component fractured or seriously weakened
Fail
4.9%class 1.4%
Fluid leaking excessively and likely to harm the environment or to pose a safety risk to other road users
Advisory
1.9%class 2.0%
Engine MIL illuminated indicating a malfunction
Fail
1.1%class 0.4%
Steering rack gaiter or ball joint dust cover damaged or deteriorated
Minor
1.1%class 0.7%
A steering ball joint with excessive wear or free play
Advisory
1.0%class 0.4%
A direction indicator lamp missing, inoperative or in the case of a multiple light source more than 1/2 not functioning
Fail
1.0%class 0.2%
Play in steering rack inner joint(s)
Advisory
1.0%class 1.1%
A shock absorber damaged to the extent that it does not function or showing signs of severe leakage
Advisory
0.9%class 2.3%
A spring or spring component fractured or seriously weakened
Advisory
0.9%class 1.3%

Wear, upkeep and luck

Tyres, pads and stone chips say more about how the car was driven and maintained than about how it was built.

Tyre tread depth not in accordance with the requirements
Advisory
28.6%class 22.9%
A brake lining or pad worn below 1.5mm
Advisory
15.4%class 8.7%
A tyre seriously damaged
Advisory
12.8%class 12.7%
Brake disc or drum excessively weakened, insecure or fractured
Advisory
8.7%class 10.1%
Brake disc or drum significantly and obviously worn
Advisory
5.8%class 3.4%
A rear registration plate lamp or light source missing or inoperative in the case of multiple lamps or light sources
Minor
3.9%class 1.2%
Child Seat fitted not allowing full inspection of adult belt
Advisory
3.7%class 2.2%
A brake lining or pad worn below 1.5mm
Fail
3.2%class 1.6%

Unconfirmed issues

Reported

Owner folklore from forums and the motoring press. Most of it never shows up in an MOT, which is why this section exists at all.

EGR cooler clogs on the D4 diesel (2014-2016 VEA engine)

Confirmed pattern

The water-cooled EGR cooler on the twin-turbo D4 diesel silts up with sooty deposits from the exhaust gas, usually throwing an engine management light or dropping the car into limp mode. Owners report the first symptoms anywhere from 47,000 to 135,000 miles; fixes range from a few hundred pounds for a valve or cooler under goodwill to £4,000-£11,000+ for a top-end rebuild or replacement engine once soot has spread through the intake. Volvo has run a safety recall on affected D4 engines over inlet manifolds melting and a fire risk linked to the same blocked system, and dealers have made partial or full goodwill payments on some out-of-warranty repairs.

Reported 47k-135k miles on D4 diesel · sources: Honest John owner reports, Volvo Forums threads (referenced via Honest John)

Automatic gearbox glitches and limp mode

Automatic gearbox only

Owners of Geartronic and Aisin automatic XC60s report jerky or delayed downshifts, gearboxes dropping into limp mode with a "transmission service required" warning, and occasional slipping, sometimes with no fault code found by the dealer. It has cropped up on cars from as low as 19,000 miles to well past 60,000, and one case needed a new TCM module at over £500. On the plug-in hybrid T8, several owners separately describe the box as laggy specifically in economy/hybrid drive mode.

Reported 19k-67k miles · sources: Honest John owner reports, Parkers owner reviews (T8 gearbox lag)

Rear trailing arm bush wear

Partly in the MOT data

Owners of 2017-on cars report the rear trailing arm bushes splitting from around 52,000 miles, needing a dealer repair (one owner quoted £540). This lines up with the measured MOT data for the large-SUV class, where suspension is the standout fault, though what's actually failing here is a bush wearing out on one arm rather than anything more structural, so a clunk on its own isn't a reason to panic.

Reported from around 52k miles on 2017-on cars · sources: Honest John owner reports, cross-referenced against segment MOT data

Early D5 diesel oil dilution

Early D5 diesel only

On early D5 diesels, unburned fuel could enter the sump during DPF regeneration cycles, raising the oil level and diluting it, which risks accelerated engine wear if unnoticed over time. Volvo addressed it with a 2010 technical bulletin covering an ECU software reflash and an oil change; most affected cars will already have had this done, but it's worth confirming on the service history for 2008-2010 D5 cars specifically.

Affected 2008-2010 D5 diesel · TSB issued 2010 · sources: Honest John owner reports and TSB reference

Tailgate gas struts wearing out

Emerging

Several owners of 2008-2017 cars separately report tailgate gas struts weakening and eventually failing, leaving the tailgate unable to hold itself up, on a roughly four-year cycle. A dealer will typically charge £500-800 for genuine struts, though aftermarket ones can be found for £12-46 each. It isn't a safety recall, just a wear item that keeps recurring rather than being a one-off.

Recurs roughly every 4 years on 2008-2017 cars · sources: Honest John owner reports

Water ingress from windscreen or roof electronics

Disputed

A handful of owners report water getting into the cabin, in one case from a windscreen that had de-bonded at around 45,000 miles, in another from the ceiling light cluster soaking the driver's floor mat, in both cases with water reaching nearby electrics. It isn't clear how common this really is versus isolated bad seals or bad luck, so treat it as worth checking rather than an established pattern.

Isolated reports, no confirmed mileage pattern · sources: Honest John owner reports

Viewing one? Ask this

Built from the two sections above.

Cold-start the D4 diesel and take it on a longer test drive if possible. An engine management light, rough running, or limp mode points to a clogged EGR cooler.
Check the service history for D4 diesel EGR cooler, valve, or inlet manifold recall work. No record of this on an older D4 with high miles means the expensive failure may still be ahead of you.
On an automatic, cycle through reverse to drive a few times and try some hard and gentle downshifts. A clonk, jerk, or hesitation before the gearbox responds suggests the transmission fault owners report.
On a T8 plug-in hybrid, drive it in pure electric or economy mode. Noticeable lag or hesitation in this mode is a known owner complaint on this variant.
Listen for creaks or clunks from the rear over speed bumps and check the tailgate holds itself open unaided. Clunking points to rear suspension bush wear; a drooping tailgate means the gas struts are on the way out.
Read the full MOT history, not just the pass/fail. A repeated suspension advisory over several tests means the underlying wear was never actually fixed.
Check the headlining near the windscreen and any ceiling light fittings for damp staining. Discolouration here can indicate a past water leak that may have reached nearby wiring.

Others in its class

Same segment (Family & large SUVs), best MOT record first. Compare before you shortlist.

How it compares

Head to head with the other popular cars in its class on reliability and common faults.