2021 Volvo S90L, 2020-2021 XC60, & XC90 R10120 Rotor and Shaft May Separate Causing a Loss of ABS

SEOCONTENT-STARTVOLVO CAR SERVICE AND PARTS BUSINESS Quality Bulletin TITLE: Recall R10120: Hydraulic Unit Model Year 2020 – 2021 XC60, XC90 and S90L GROUP: 5200 CAT/NO: R10120 ISSUING DEPARTMENT: Product, Safety and Compliance CAR MARKET: United States and Canada REVISIONS: ISSUE DATE: 2021-09-17 STATUS DATE: 2021-09-17 Page 1 of 3 “Right first time in Time” Produced and printed in the USA and available as an electronic document. © 2021 VOLVO CAR USA, LLC A. RECALL R10120 DESCRIPTION B. VEHICLES INVOLVED C. PARTS INFORMATION/PARTS RETURN D. OWNER NOTIFICATION E. VEHICLES IN RETAILER INVENTORY F. RETAILER RESPONSIBILITY G. TECHNICIAN COMPETENCY REQUIREMENT H. REIMBURSEMENT PROCEDURES & ALLOWANCE A. RECALL R10120 DESCRIPTION Volvo Car USA LLC and Volvo Car Canada LTD on behalf of Volvo Car Group, have decided to launch Recall R10120 on certain model year 2020-2021 XC60, XC90 and S90L vehicles. Volvo Cars investigations have identified that there may be a risk that certain welding between the Hydraulic brake unit motor’s rotor shaft and the magnet package (armature) can partially or fully be missing. The welding defect can potentially result in a failure if magnet segments aren’t sufficiently welded. The risk of a potential slip between the motor shaft and the magnet package (armature) is likely to appear suddenly in situations when high motor torque* is requested and/or in combination with high motor rpm. Decreased motor performance will be detected and result in a redundant hydraulic fall back. – No brake boost – ABS disabled Page 2 of 3 2021-09-17 Quality Bulletin R10120 – ESC disabled – All other hydraulic control functions are disabled except EBD (Electronic brake force distribution) – Red Brake warning light, ABS and ESC warning light activated. – IPB (Integrated parking brake) related functions remain active. FSI (Fallback Support by IPB) available. *High motor torque is requested when a high pressure and/or pressure gradient are required. Those situations are relatively rare i.e. hard emergency braking. To remedy the concerned vehicles, Volvo Cars will replace the Hydraulic Unit, free of charge to the customer. A total of 9 U.S. and 1 Canadian vehicle are eligible for this recall. WHAT SHOULD YOUR CUSTOMERS DO NOW? We have no reports of incidents related to the issue. Due to the limited number of involved vehicles Volvo Cars Customer Care will call each of the owners and provide them with additional information and guidance on how best to have this recall repair completed. Should customers contact you requesting information on their vehicle please direct them to Customer Care. B. VEHICLES INVOLVED NOTE: RETAILER MUST CONFIRM VEHICLE ELIGIBILITY PRIOR TO BEGINNING THE REPAIR FOR THIS RECALL. Vehicle eligibility must be confirmed: • Vehicle Inquiry – Warranty Vehicle Inquiry where the message “Recall R10120 Hydraulic Unit” will appear for eligible vehicles, F4=History from the main Inquiry menu must be selected to confirm Recall R10120 has not been completed. Eligibility can also be confirmed in TIE. All vehicles must be checked for any incomplete Recalls, Service Campaigns or Service Actions. All open Recall, Service Campaign or Service Action repairs must be completed. C. PARTS / PARTS RETURN Please refer to Parts Bulletin R10120. D. OWNER NOTIFICATION Owners will be contacted by the Customer Care team. If the owner is not able to be reached an owner’s notification letter will be sent out that will notify the owner of this recall instructing them to contact their retailer and request an appointment to have this repair completed. E. VEHICLES IN RETAILER INVENTORY It is a violation of federal law for a retailer to deliver any new Volvo that is eligible for a recall. Retailers are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a retailer could result in a civil penalty of up to$22,723 per vehicle. Correct all vehicles in your vehicle inventory before delivery. 2021-09-17 Page 3 of 3 Quality Bulletin R10120 Used Vehicles in Retailer Inventory VCUSA is ordering the stop-delivery of affected vehicles in auction and dealer inventory until the recalled item can be inspected/repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with our commitment to safety. Additionally, while Federal law does not prohibit the sale of used vehicles with open recalls, the sale of such cars could violate certain state laws and create liability on behalf of the Retailer. What does this mean for customers? Customers will not be able to take delivery of affected vehicles until the recall has been completed. F. RETAILER RESPONSIBILITY All vehicles qualifying for this recall must be repaired prior to a customer taking possession of the vehicle. G. TECHNICIAN COMPETENCY REQUIREMENT The technician competency requirement for this campaign repair is Level 2 – Certified Tech for Repair. H. REIMBURSEMENT PROCEDURES & ALLOWANCE Recall R10120 claims should be submitted using the LONG FORM application only. Claim Type: R10120 Cause Code: 02 CSC Code: XW Main OP: 97791 Failed Part No.: 36011717 Operation Number Repair Description 97791-2 Brake boost replace acc. to QB-R10120 Type & Engine OP Variant Group Time Number of Affected Vehicles 238/BR S90L – Plug In Hybrid 2.5 (1) 246/BR XC60 II – Plug In Hybrid 2.5 (2) 256/BR XC90 II – Plug In Hybrid 2.6 (7) 36004-2 Software control download module Type & Engine OP Variant Group Time Number of Affected Vehicles 238/BR S90L – Plug In Hybrid .7 (1) 246/BR XC60 II – Plug In Hybrid .7 (2) 256/BR XC90 II – Plug In Hybrid .7 (7) Labor times provided are current at the time of release and are subject to change: Claims will be paid at the time in effect on the repair date.
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VOLVO CAR SERVICE AND PARTS BUSINESS Parts Bulletin TITLE: Recall R10120: Hydraulic Unit Model / Year: 2020 – 2021 XC60, XC90 and S90L GROUP: 52 CAT/NO: R10120 CAR MARKET: United States and Canada REVISIONS: ISSUE DATE: 2021-09-16 STATUS DATE: 2021-09-16 Page 1 of 2 “Right first time in Time” Produced and printed in the USA and available as an electronic document. © 2021 VOLVO CAR USA, LLC Reference Bulletins: QB 10120 Volvo Car USA LLC and Volvo Car Canada LTD on behalf of Volvo Car Group, have decided to launch Recall R10120 on certain model year 2020-2021 XC60, XC90 and S90L vehicles. Volvo Cars investigations have identified that there may be a risk that certain welding between the Hydraulic brake unit motor’s rotor shaft and the magnet package (armature) can partially or fully be missing. The welding defect can potentially result in a failure if magnet segments aren’t sufficiently welded. The risk of a potential slip between the motor shaft and the magnet package (armature) is likely to appear suddenly in situations when high motor torque* is requested and/or in combination with high motor rpm. Decreased motor performance will be detected and result in a redundant hydraulic fall back. – No brake boost – ABS disabled – ESC disabled – All other hydraulic control functions are disabled except EBD (Electronic brake force distribution) – Red Brake warning light, ABS and ESC warning light activated. – IPB (Integrated parking brake) related functions remain active. FSI (Fallback Support by IPB) available. *High motor torque is requested when a high pressure and/or pressure gradient are required. Those situations are relatively rare i.e. hard emergency braking. Page 2 of 2 2021-09-16 Parts Bulletin 52-R10120 To remedy the concerned vehicles, Volvo Cars will replace the Hydraulic Unit, free of charge to the customer. A total of 9 U.S. and 1 Canadian vehicle are eligible for this recall. The following part numbers apply: Part Number Description Qty 31680105 S90L Hydraulic Unit 1 36011717 XC60, XC90 Hydraulic Unit 1
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1 Any City, US 12345-6789 October 25, 2021 NHTSA RECALL 21V-716 IMPORTANT SAFETY RECALL mis NOTICE APPLIES TO YOUR VEHICLE, VIN Dear Volvo A. Owner, This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Volvo Car USA LLC (Volvo) on behalf of Volvo Car Group, has decided that a defect which relates to motor vehicle safety exists in certain model year 2020-2021 S901, XC60 and XC90 Volvo vehicles. The reason for Recall R10120: Volvo Cars investigations have identified that there may be a risk that certain welding between the Hydraulic brake unit motor’s rotor shaft and the magnet package (armature) can partially or fully be missing. The welding defect can potentially result in a failure if magnet segments aren’t sufficiently welded. The risk of the potential slip between the motor shaft and the magnet package (armature) is likely to appear suddenly in situations when high motor torque* is requested and/or in combination with high motor rpm. This could lead to increased risk of injury or crash. Decreased motor perfon11ance will be detected and result in a redundant hydraulic fall back. – No brake boost – Antilock Brake System (ABS) disabled – Electronic Stability Control (ESC) – All other hydraulic control functions are disabled except Electronic brake force distribution (EBD) – Red Brake warning light, ABS and ESC warning light activated. – Integrated parking brake (IPB) related functions remain active. FSI (Fallback Support by IPB) available. *high motor torque is requested when a high pressure and/or a rapid change in pressure are required. Those situations are relatively rare i.e. hard emergency braking. Recall action: Rl0120: The corrective action is to replace the Hydraulic Unit, free of charge. Please contact your authorized Volvo retailer to schedule an appointment for the repair to be completed. This procedure will be completed at no cost and can take up to four hours to complete, however due to service scheduling your Volvo retailer may require your vehicle for a longer period. If you no longer own the vehicle described in this letter, please help us to update our records by sending us the updated owner information. Please refer to our contact information in this letter. Please contact: lf you have any questions, please contact your Volvo retailer. If your retailer is unable to answer your questions, please contact Volvo Customer Care Center: 1800 Volvo Place Mahwah, NJ 07430 Or by phone at l -800-458-1552, 24 hours a day, 7 days a week. You may also contact us by going to https://volvocars.us/support We have advised the National Highway Traffic Safety Administration (NHTSA) that we are conducting this recall. If you are unable to have this procedure performed without charge, and within a reasonable period of time, you may contact the NHTSA Administrator at: National Highway Traffic Safety Administration 1200 New Jersey A venue, SE. Washington, DC 20590 Or you can call the toll-free Vehicle Safety Hotline at 1-800-327-4236 (TTY: l-800-424-9153). You may also go to their website, https://www.safercar.gov. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. To learn more about Volvo safety recalls, scan the QR Code below or visit us at: https ://www.volvocars.com/us/ o, vn/additional-choices/recall-information Your safety and continued satisfaction with your Volvo and the Volvo organization are very important to us . We apologize for any inconvenience this may cause, and we are working to have this important Service completed as quickly as possible. Sincerely, ✓ Vincent D’Auria Senior Manager Product, Safety and Compliance – Regulatory & Compliance 1-800-458-1552
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Vincent D’Auria Senior Manager Product, Safety & Compliance – Regulatory & Compliance September 15, 2021 Subject: Recall R10120 TO: All U.S. and Canadian Volvo Retailers NEW VEHICLES IN RETAILER INVENTORY It is a violation of federal law for a retailer to deliver any new Volvo that is eligible for a recall. Retailers are advised to check all vehicles in inventory for recall eligibility and repair immediately. Violation of this requirement by a retailer could result in a civil penalty of up to $22,723 per violation. Correct all vehicles in your new vehicle inventory before delivery. USED VEHICLES IN RETAILER INVENTORY Volvo Car USA is ordering the stop-delivery of affected vehicles in auction and retailer inventory until the recalled item can be repaired. Stopping the delivery of affected used vehicles until the recall is complete is consistent with Volvo’s commitment to safety. Additionally, while Federal law does not prohibit the sale of used vehicles with open recalls, the sale of such cars could violate certain state laws and create liability on behalf of the retailer. What does this mean for customers? Customers will not be able to take delivery of affected vehicles until the recall has been completed. When will this be resolved? Volvo Car USA LLC and Volvo Car Canada LTD on behalf of Volvo Car Group, have decided to launch Recall R10120 on certain model year 2020-2021 S90L, XC60 and XC90 vehicles. Volvo Cars investigations have identified that there may be a risk that certain welding between the Hydraulic brake unit motor’s rotor shaft and the magnet package (armature) can partially or fully be missing. The welding defect can potentially result in a failure if magnet segments aren’t sufficiently welded. The risk of the potential slip between the motor shaft and the magnet package (armature) is likely to appear suddenly in situations when high motor torque* is requested and/or in combination with high motor rpm. Decreased motor performance will be detected and result in a redundant hydraulic fall back. – No brake boost – ABS disabled – ESC disabled Volvo Car USA LLC Page 1 of 2 270 Three Point Drive Ridgeville, SC 29472 Telephone +1-201-768-7300 volvocars.us – All other hydraulic control functions are disabled except EBD (Electronic brake force distribution) – Red Brake warning light, ABS and ESC warning light activated. – IPB (Integrated parking brake) related functions remain active. FSI (Fallback Support by IPB) available. *high motor torque is requested when a high pressure and/or pressure gradient are required. Those situations are relatively rare i.e. hard emergency braking. To remedy the concerned vehicles, Volvo Cars will replace the Hydraulic Unit, free of charge to the customer. A total of 9 U.S. and 1 Canadian vehicle are eligible for this recall. Vehicle eligibility must be confirmed: • Vehicle Inquiry – Warranty Vehicle Inquiry where the message “Recall R10120 Hydraulic Unit” will appear for eligible vehicles, F4+History from the main Inquiry menu must be selected to confirm Recall R10120 has not been completed. Eligibility can also be confirmed in TIE. • Recall R10120 eligible vehicles not yet delivered to end customers must be corrected prior to delivery. All vehicles must be checked for any incomplete recalls or service campaigns or service upgrades. All open Recall, Service Campaigns or Service Action repairs must be completed. If you have any questions concerning this recall or your retailers affected vehicles, please send an e-mail with your retailer code to recall@volvocars.com. OWNER NOTIFICATION An owner notification letter will be sent out that will notify the owner of this recall. PARTS / PARTS RETURN Please review Parts Bulletin R10120 once available. CLAIM SUBMISSION Claim submission instructions will be made available in the Quality Bulletin. RETAILER RESPONSIBILITIES Retailers must perform this recall campaign on eligible vehicles regardless of miles/kilometers or vehicle age. All work performed under this recall is free of charge to the owner. As the safety of our customers is our upmost priority, we are taking full responsibility to ensure the highest quality and safety standards for our cars. If you have questions about this recall or any other field service action, please contact me or any member of the Product Safety and Compliance office. Your cooperation in completing this important recall is greatly appreciated. Drive Safely, Vincent D’Auria Senior Manager Product, Safety and Compliance – Regulatory & Compliance 201-647-0004 vincent.dauria@volvocars.com Page 2 of 2
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