Fault File
All models / All cars / Family & large SUVs / Volvo XC90

Volvo XC90

All generations and engines together · 59,197 MOT tests in the 2025 data · typical mileage at age 7: 76k

First-time failure at age 7
16.9%
Across 5,621 tests. The average across all tracked models is 19.5%.
Rank at age 7
93 of 239
1 = lowest failure rate among the models tracked.
Typical mileage at age 7
76k 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 XC90Class 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. 21,584 tests in this band.

A suspension pin, bush or joint excessively worn
Advisory
12.9%class 6.7%
A steering ball joint with excessive wear or free play
Advisory
5.7%class 0.4%
A suspension joint dust cover severely deteriorated
Minor
3.4%class 0.6%
A suspension pin, bush or joint excessively worn
Fail
3.0%class 0.7%
Play in steering rack inner joint(s)
Advisory
2.5%class 1.1%
A steering ball joint with excessive wear or free play
Fail
2.3%class 0.4%
Fluid leaking excessively and likely to harm the environment or to pose a safety risk to other road users
Advisory
2.2%class 2.0%
A shock absorber damaged to the extent that it does not function or showing signs of severe leakage
Advisory
1.1%class 2.3%
Steering rack gaiter or ball joint dust cover missing or no longer prevents the ingress of dirt etc
Fail
0.8%class 0.4%
Steering rack gaiter or ball joint dust cover damaged or deteriorated
Minor
0.7%class 0.7%

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
24.9%class 22.9%
A brake lining or pad worn below 1.5mm
Advisory
16.5%class 8.7%
A tyre seriously damaged
Advisory
14.2%class 13.4%
Brake disc or drum excessively weakened, insecure or fractured
Advisory
6.8%class 10.1%
Child Seat fitted not allowing full inspection of adult belt
Advisory
5.6%class 2.2%
Brake disc or drum significantly and obviously worn
Advisory
5.0%class 3.4%
Number plate inscription missing or illegible
Advisory
4.0%class 1.5%
A tyre seriously damaged
Fail
3.9%class 2.0%

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.

D5 diesel timing belt tensioner and swirl flap failures

Diesel (D5/2.4D) only

On pre-2015 D5 and 2.4D diesels the timing belt tensioner can let go well short of its interval, sometimes from around 50-65k miles, and if it does the belt jumps and the engine destroys itself, a repair that can run to several thousand pounds. Volvo's own guidance has the belt, tensioner, pulleys and water pump changed together at 60,000 miles or 4 years rather than the longer figure once quoted, which owners read as a quiet admission the original interval was too long. The same engines are also known for inlet manifold swirl flaps snapping off any time after about 3 years old, and flaps have been reported failing again even after a first replacement.

Tensioner failures from ~50-65k miles, swirl flaps from 3 years old · sources: Honest John, Volvo/Matthews Volvo Site owner forums

AWD angle gear failure

Confirmed pattern

The angle gear that carries drive from the gearbox to the rear differential on four-wheel-drive cars is a known weak point, with a reputation for failing in cold weather. Volvo has described it in owner correspondence as an inherent fault and offered goodwill contributions on a sliding scale by mileage, though it never ran a full recall. Repairs are typically well over a thousand pounds, and more if the failure has also damaged the transmission output side.

Reported across the mileage range, worse in winter · sources: Honest John, Volvo Owners Club / Matthews Volvo Site forum

Geartronic automatic gearbox trouble, especially towing

Emerging

The Geartronic auto box fitted across most UK-spec cars is repeatedly flagged by tow-car owners as marginal, with the transmission oil cooler seen as too small for sustained hauling on hills. Symptoms range from hesitant or flared changes to a gearbox that revs without engaging after a long motorway run. Some cases clear up with a fluid flush, others need a valve body or full rebuild running into four figures, and the same fault pattern turns up across Volvo owner and towing forums rather than in one isolated report.

Reported mainly on towing cars, any age/mileage · sources: Honest John, Volvo Owners Club forum, Caravan Club / towing forums

Sagging air suspension and compressor faults

Partly in the MOT data

Cars fitted with the optional Four-C adaptive air suspension (mainly post-2015 cars on Plus and Ultra trim) are a recurring source of "Suspension Service Required" warnings, one corner sitting low overnight, and compressor or air spring failures once out of warranty. Suspension is the fault this model's MOT data flags most, and while a leaking air spring itself is a pre-MOT money pit rather than something that necessarily fails the test straight away, it points at the same underlying soft spot the test data is picking up. Expect four figures for a spring or compressor, more if several corners need doing.

Reported from 4-5 years old on air-suspension cars · sources: Volvo Owners Club / SwedeSpeed forums, Matthews Volvo Site, RepairPal

Infotainment reboots and 12V electrical gremlins

Emerging

Second-generation cars (2015 on) get recurring complaints about the Sensus infotainment system rebooting itself, software updates that fix a glitch only for it to come back, and 12V battery or charging faults that can cause a wider electrical shutdown. Owners report repeat dealer visits without the problem fully going away. It is not tied to one engine or trim and turns up on both diesel and plug-in hybrid cars.

Reported from early ownership onward, any mileage · sources: Honest John, Volvo Owners Club forum

T8 plug-in hybrid battery degradation

Plug-in hybrid (T8) only

On T8 hybrid cars the high-voltage battery pack can lose range faster than the brochure figure suggests, with some owners reporting electric-only range down to a fraction of new after 5-6 years, and a smaller number of early or rapid failures needing a full pack replacement within a few years of purchase. Volvo has sometimes offered a partial goodwill contribution rather than a free fix once the car is out of warranty. Only affects the T8 plug-in hybrid, not the diesel or mild-hybrid petrol range.

Reported from ~4 years/40k miles onward on T8 cars · sources: Matthews Volvo Site and other owner forums

Viewing one? Ask this

Built from the two sections above.

Ask for timing belt, tensioner and water pump receipts on any pre-2015 D5 diesel. Nothing done by 60,000 miles or 4 years means budget for it now, or the engine is a gamble.
Rev it cold and listen for a rattle or rough idle from the inlet side on D5/2.4D diesels. Can point to a swirl flap starting to break up before it drops into the inlet.
Move off from a stop and through a tight, low-speed turn on any four-wheel-drive car. A clonk or knock from underneath is the classic sign of a worn angle gear.
If the car has a tow bar, ask how it was used and try to feel the gearbox under load. Flared or hesitant changes on a hill point to the Geartronic gearbox struggling with towing.
Walk around the car after it has sat overnight and compare ride height corner to corner. One side sitting visibly lower is a leaking air spring on cars with adaptive air suspension.
Cycle through every infotainment screen and check for a recent low-battery or charging warning. Repeated reboots or a stored 12V fault suggest the electrical gremlins some owners report.
On a T8 hybrid, check the indicated EV-only range against the original spec figure. A big shortfall means the high-voltage battery has degraded and a costly pack may be on the horizon.

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