Volvo Recalls Over 14,000 Electric and Plug-In Hybrid Vehicles for Brake Defect
Volvo has announced a recall affecting more than 14,000 electric and plug-in hybrid vehicles because of a potentially serious brake system defect.
The 2025 Volvo Electric and EV Brake Defect problem originates from a software glitch in the Brake Control Module, which can malfunction during extended downhill coasting in certain drive modes.
This defect may result in a complete loss of braking power, putting drivers at risk. The recall covers a range of models from 2020 through 2026, including popular SUVs and sedans such as the XC60, XC90, C40, and S60.
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What’s Causing the Volvo Brake Failure Risk?
The issue is linked to software version 3.5.14, which affects the Brake Control Module. If a driver coasts downhill for more than 100 seconds without pressing the accelerator or brake pedal—while in “B” mode for plug-in hybrids or “One Pedal Drive” mode for battery electric vehicles—the system may disable braking entirely.
In some cases, pressing the brake afterward may not restore functionality, posing a significant safety hazard.
Which Volvo Models Are Affected by this Recall?
The following Volvo models are included in the July 2025 recall related to a brake software defect:
- 2023 Volvo C40 Recharge (BEV)
- 2025 Volvo EC40
- 2023–2024 Volvo XC40 Recharge (BEV)
- 2020–2026 Volvo XC90 Recharge (PHEV)
- 2022–2026 Volvo XC60 Recharge (PHEV)
- 2023–2025 Volvo S60 Recharge (PHEV)
- 2024–2025 Volvo V60 Recharge (PHEV)
- 2025–2026 Volvo EX40
- 2025 Volvo S90 Recharge (PHEV)
These vehicles are equipped with a specific version of brake control software that may cause braking to be disabled under certain conditions.
The risk is particularly associated with extended coasting while in regenerative braking modes, where neither the brake nor accelerator pedal is used.
What Volvo Is Doing to Fix the Brake Problem
To address the brake defect, Volvo is issuing a software update for impacted electric and plug-in hybrid models.
The update, software version 3.6.4, is designed to correct the issue in the Brake Control Module that could cause braking to be disabled after extended coasting in regenerative braking modes.
For most affected vehicles, the fix will be delivered remotely through over-the-air (OTA) updates. Owners will be notified directly through their vehicle’s infotainment system once the update is available, allowing them to install it without visiting a dealership.
If a vehicle is not eligible for OTA updates—or if the owner prefers—the software can also be installed free of charge at an authorized Volvo dealership.
Volvo will begin mailing official recall letters on August 6, 2025. These notifications will provide details on how to complete the update and any additional steps that may be required.
Until the update is installed, Volvo advises owners to avoid extended downhill coasting in “B” mode or One Pedal Drive, as these driving conditions may trigger the braking issue.
Steps Volvo Owners Should Take Right Away
If you own one of the affected Volvo electric or plug-in hybrid vehicles, follow these steps to ensure your safety and complete the necessary recall update:
- Avoid high-risk driving modes: Until the software update is installed, do not use “B” mode (for plug-in hybrids) or “One Pedal Drive” mode (for electric vehicles), especially during extended downhill coasting. These modes can trigger the braking issue under specific conditions.
- Watch for an OTA update notification: Volvo is rolling out the software fix (version 3.6.4) via over-the-air updates for most vehicles. If your vehicle is eligible, you’ll receive a notification on the infotainment screen with instructions to install the update.
- Look out for an official recall notice: Volvo will begin mailing recall letters starting August 6, 2025. These notices will provide confirmation of the recall and guidance on how to complete the update process.
By taking these steps promptly, you can help prevent the risk of brake failure and ensure your Volvo is operating safely.
Do You Have Lemon Law Rights If the Problem Persists?
If your Volvo continues to experience brake issues even after receiving the recall software update, you may have rights under your state’s lemon law.
These consumer protection laws exist in all 50 states and are intended to ensure that drivers are not stuck with a vehicle that has serious and unresolved defects.
Lemon laws generally require manufacturers to replace, repurchase, or compensate owners when a defect significantly affects a vehicle’s use, safety, or value—and the issue isn’t properly repaired after a reasonable number of attempts.
The specific requirements to present a claim vary by state. A vehicle may qualify as a lemon if the defect has been subject to repeat warranty repairs or has been out of service for an extended number of days due to warranty repairs.
To protect your potential claim, it’s important to keep detailed records of all repair attempts, communications with the dealer or manufacturer, and time the vehicle spent out of service.
You should also report the continued problem in writing and allow the manufacturer another opportunity to fix it.
Many lemon law attorneys offer free consultations and only collect fees if your case is successful—fees that are typically paid by the manufacturer.
As electric and hybrid vehicles become more common, Lemon Laws are evolving to include defects related to software and over-the-air updates, such as the type of brake control failure reported in this recall.
If the brake problem continues after the software fix, you may still have legal options. Consulting with a lemon law attorney can help you determine whether your vehicle qualifies and what steps to take next.
When to Speak With a Lemon Law Attorney About Your Volvo
If your Volvo continues to have brake failures or related safety problems after multiple repair attempts or after receiving the recall update, you may be entitled to compensation under your state’s Lemon Law.
Since 2009, the Lemon Law Experts have helped thousands of consumers recover millions of dollars for defective vehicles.
You can contact a qualified Lemon Law expert for a free consultation to determine whether your vehicle qualifies.
Don’t ignore ongoing safety concerns—legal support is available to help you pursue the resolution you deserve.
Citations
- National Highway Traffic Safety Administration. “Safety Recall Report: 25V392 – Brake Control Module Software Defect.” NHTSA, 2025, https://static.nhtsa.gov/odi/rcl/2025/RCLRPT-25V392-9729.pdf.
- National Highway Traffic Safety Administration. “Recall Completion Report: 25V392 – Brake Control Module Software Defect.” NHTSA, 2025, https://static.nhtsa.gov/odi/rcl/2025/RCAK-25V392-5360.pdf.
- “Volvo Recalls 14,000 EVs and PHEVs from 2020-2026.” Reddit, 2025, https://www.reddit.com/r/electricvehicles/comments/1lgc7o9/volvo_recalls_14000_evs_and_phevs_from_20202026/.
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