The Most Recent Issue with the Volvo EX90 Could Literally Fall on You | Carscoops

      A recent recall highlights how an error from a supplier led to tailgate issues in a luxury electric SUV that is poised for significant updates.

      The recall affects 1,119 units of the EX90 model produced between April 2024 and February 2025.

      Volvo has indicated that defective tailgate components from a supplier may lead to unexpected failures.

      Notifications will be sent to owners on November 18, and repairs will be provided at no cost.

      The all-electric Volvo EX90 has many appealing features, but its launch has faced challenges. Ongoing software issues have delayed its introduction and necessitated major upgrades for the 2026 model year.

      Nevertheless, Volvo must still resolve concerns with the 2025 EX90, which is now subject to a new recall in the United States.

      According to a recall notice issued by the National Highway Traffic Safety Administration (NHTSA) on September 30, the 2025 EX90 has a tailgate flaw that may pose a safety hazard.

      Volvo has reported that the spindle nut can disconnect from the aluminum tube while the tailgate is in an open position. If the power-operated tailgate drive unit becomes detached, the spindle may unintentionally release, resulting in the tailgate slamming shut unexpectedly.

      Identifying the Problem

      Volvo attributes the issue to improper handling of components at a supplier, where faulty parts were mistakenly sorted with acceptable ones. The recall affects a total of 1,119 vehicles, all manufactured between April 22, 2024, and February 17, 2025.

      The company first identified a possible issue in late March after a report of a tailgate spindle separation. A subsequent incident occurred a month later during internal testing, leading to a more thorough investigation into the underlying cause.

      Next Steps

      Owners of the affected vehicles will be notified about the recall starting November 18. Dealers have been directed to replace both power-operated tailgate drive units at no charge.

      To avoid similar issues in the future, Volvo has stated that its supplier has automated the quality control process, using a robot to place rejected parts into a locked container instead of allowing them to mix with approved items.

      Just weeks before this recall, Volvo announced that the 2026 EX90 will feature a new 800-volt electrical system with the capability of 350 kW charging, a significant increase from the previous model's 250 kW limit. This update promises enhanced performance and improved efficiency, suggesting a more refined driving experience once these initial challenges are resolved.