Volvo Recall 2025: Software Glitch in Plug-In Hybrids Triggers Dangerous Braking Failure — Hundreds Still Unfixed

In 2025, Volvo issued a critical safety recall affecting over 11,000 plug-in hybrid (PHEV) and electric vehicles (BEV) due to a software glitch in the brake control module that can lead to complete brake failure during long downhill coasting. Despite urgent warnings, as of early August, about 600 vehicles remain unrepaired. This article dives into what caused the defect, which models are affected, owners’ risks, and what drivers need to do now.

🚨 Why This Matters: Unintended Acceleration and Brake Loss

On June 12, 2025, Volvo filed a recall under NHTSA campaign 25V-392 (manufacturer recall R10329) for select PHEV and BEV models produced between 2020 and 2026 due to a software bug identified in version 3.5.14 of the Brake Control Module. This glitch can disable braking entirely if the vehicle coasts downhill for at least 100 seconds (1 minute and 40 seconds) in regenerative modes like “B mode” or “One Pedal Drive” even without pressing the brake or accelerator pedals (thebrakereport.com, electrive.com).

Despite a recall rollout and over-the-air (OTA) software update, about 1,000 vehicles hadn’t received the fix by mid-July, and 600 remained unrepaired as of early August, prompting NHTSA to issue a rare urgent “Do Not Drive” warning (nhtsa.gov).

A Real-World Nightmare: A Terrifying Steep-Downhill Incident

A high-profile case spotlighted the urgency of the defect. In May 2025, Volvo owner Peter Rothschild, driving a 2025 XC90 PHEV down a steep mountain road in Northern California, experienced total brake loss. Footage shows his vehicle accelerating out of control despite brake application. He steered off-road to stop but not before side airbags deployed and his SUV sustained serious damage (wsj.com).

Volvo confirmed the issue emerged from a software package alongside a previous rearview-camera recall fix. Once the braking issue was identified, Volvo halted installation of the faulty software and began issuing the corrected version immediately (wsj.com).

Models Affected by the Volvo Recall

The recall affects approximately 14,000 PHEV and BEV vehicles in the U.S., across multiple models and model years. The most affected models include:

• 2022–2026 XC60 Recharge (PHEV)

• 2020–2026 XC90 Recharge (PHEV)

• 2023–2025 S60 Recharge (PHEV)

• 2024–2025 V60 Recharge (PHEV)

• 2023 C40 Recharge (BEV)

• 2023–2024 XC40 Recharge (BEV)

• 2025 EC40 BEV

• 2025–2026 EX40 PHEV

• 2025 S90 PHEV (tflcar.com, electrive.com, nhtsa.gov)

According to NHTSA documentation, a total of roughly 11,469 vehicles were included in the recall program, but some news outlets report total exposure closer to 14,014 units (roadandtrack.com).

What Caused the Braking Defect?

Volvo traced the issue to software version 3.5.14, which was deployed starting April 25, 2025. The faulty code modifies the logic in the Brake Control Module, leading to brake loss after extended downhill coasting in certain regenerative modes. Interestingly, the defective software was originally part of an update to fix a rear-view camera issue and included unrelated enhancements to lane-keeping assist, tire pressure monitoring, and road sign recognition. Unfortunately, this software inadvertently compromised the braking system (electrive.com).

How Volvo Fixed the Issue

Starting June 16, 2025, Volvo began rolling out a corrected software version (3.6.4) via over-the-air updates and at authorized dealerships, free of charge to vehicle owners. Owner notification letters were scheduled to be mailed beginning August 6, 2025 (electrive.com). The remedy restores proper brake control during regenerative braking and resolves the defect without hardware changes (electrive.com).

Risks of Driving Without the Fix

Until your vehicle has the corrected software installed, Volvo and NHTSA strongly advise:

• Not driving at all, if possible.

• If driving is absolutely necessary, disable regenerative braking (“B mode” or “One Pedal Drive”), especially in hilly or mountainous areas.

• Understand that pressing the brake pedal after extended coasting may trigger complete brake failure, dramatically increasing crash risk (nhtsa.gov, roadandtrack.com, thesun.co.uk).

Step-by-Step: What Owners Should Do Now

1. Check Your Vehicle Status
   Enter your VIN on the NHTSA recall lookup tool or visit Volvo’s official recall website to verify if your vehicle is included in the R10329 / 25V-392 campaign (nhtsa.gov).

2. Avoid At-Risk Driving Modes
   Until you’re updated, do not use “B mode” or “One Pedal Drive,” and limit downhill driving without applying the brake longer than 100–110 seconds (carcomplaints.com).

3. Get the Software Update
   If eligible, install the recall remedy via over-the-air update through your in-car system, or schedule a free service appointment at an authorized Volvo dealer (electrive.com).

4. Don’t Ignore Official Notices
   Recall letters are being mailed starting August 6, 2025. Keep track of your memos and act promptly (lemonlawexperts.com).

5. Seek Refund if Already Paid
   If you’ve paid for repairs related to this issue before the recall was issued, contact Volvo for potential reimbursement (thebrakereport.com).

Why This Recall Is Causing Industry-Wide Concern

Today’s vehicles rely heavily on software-defined systems. While OTA updates and digital fixes are increasingly common, this incident illustrates a major risk: fixing one problem can create another. Safety advocates warn that automakers lack standardized protocols for validating software patches impacting critical systems like braking (wsj.com, electrive.com, thebrakereport.com, thesun.co.uk).

In fact, over 6.8 million vehicle recalls in 2024 were fixed remotely—up from 2.7 million in 2023. Industry insiders are questioning whether regulators and manufacturers are keeping pace with software complexity (wsj.com).

Safety Tips and Best Practices

• Confirm your vehicle’s software version; if it’s version 3.5.14, you may be at risk.

• Disable regenerative driving modes until your software is updated.

• Avoid risky driving conditions, especially mountainous or steep roads, until the fix is applied.

• Report incidents of brake loss to Volvo and NHTSA.

Link to the Pessada Education Center

For vehicle owners seeking reliable, in-depth information on recalls, repairs, and overall vehicle safety, visit the Pessada Education Center for expert guidance and resources designed to keep you informed and on the road safely.