2025 VOLVO EX90 Complaints

The GHCA failed while AC charging at home, and the vehicle made loud banging noises. AC charging is no longer possible, and a replacement part is still backordered with no ETA over three months later. A corporate case has been filed with Volvo and they are effectively unresponsive, only emailing me once a few weeks after the case was created, saying that they would promptly reply to any of my responses, but have not replied for almost a month after my immediate response.

The instrument panel displays symbol for exterior lights malfunction and the vehicle status screen reports “1 serious issue detected – Headlight fault – Book a service”. The high and low beams appear to function normally on both sides of the car. The daytime running lights (white) around the headlight are only illuminated on the drivers side; the passenger side running lights are not working. This issue is intermittent. It first occurred within one day of ownership and has recurred about once per week since then. Service department stated in mid-December that this is a software issue that will be fixed in a future update, but there hasn’t been one and the issue still presents. Car software is currently version 1.4.15, and I believe has been since delivery.

While Level 2 charging at home from a NEMA 14-50 receptacle using the Volvo-supplied cable/adapter, charging stopped unexpectedly accompanied by a loud thunk. The central computer restarted and presented a profile setup routine as if the car was new. Stored settings were not retained. Repeated attempts to re-initiate charging resulted in ‘Charging fault’ notifications on the instrument panel and a solid red light on the charging port indicator. The car can no longer charge with AC power, but still charges with Level 3 DC equipment. Also, the car software doesn’t seem to recognize that there is a problem with the vehicle. It shows the status as ‘everything is OK’.

The onboard charger (ghca) failed, destroying my evse and tripping the circut breaker in my electrical panel. It took 3.5 weeks for the replacement part to come in and be installed. On another occasion, the pilot assist adas presented an error and was unavailable until the computer was rebooted.

The Grid to High Voltage Converter A (GHCA) is a critical, often failing, component in 2025+ Volvo EX90 and Polestar 3 electric vehicles that converts AC grid power to high-voltage DC for the battery has failed 5 times in my car with no fix from Volvo in the foreseeable future. There are some reports on reddit/ex90 and other owner forums that these failures can cause unsafe voltages and have blown up home chargers. It seems like it is getting to the point where they need to be forced to issue a recall for this part and compensate owners.

Ongoing Software Issues From shortly after delivery through now, the vehicle experiences frequent and recurring warning messages and system failures, including but not limited to: Suspension system warnings Driver assistance and self-driving feature failures One-pedal driving malfunctions Parking camera and sensor errors Other system warnings that appear to be software-related While the vehicle was often still technically drivable, these issues regularly caused the car to operate at reduced functionality, with key safety and convenience features disabled. Although software updates have reduced the frequency of these issues, they still occur intermittently and often require a vehicle reset or time to resolve. Because of these persistent and unpredictable warnings, my family and I have avoided taking this vehicle on long trips out of concern that the car may become unsafe or inoperable while traveling. The vehicle was brought in for service in December 2024 in an attempt to address these software-related issues; however, the service did not resolve the problem at that time. Hardware Failure #1 – GHCA In January 2025, the vehicle experienced a failure of the GHCA component, rendering the all-electric vehicle unable to charge. This occurred shortly after purchase. Service appointment booked: January 27, 2025 Vehicle in shop: aprox 30 days The vehicle was out of service for approximately one full month. During this time, I shared my experience on Reddit due to the severity of the issue and the vehicle’s newness. That post received over 350,000 views, and numerous Volvo EX90 owners reported experiencing the same GHCA failure—many stating they had required multiple replacements of the same component. This strongly suggests a widespread defect rather than an isolated incident. Hardware Failure #2 – GHCA (Repeat Failure) On February 3, 2026, the GHCA failed again, and the vehicle was returned to the dealership for service with no ETA on a fix.

Recall R10342 Power Operated Tailgate (POT) Drive Unit separation was not remedied by dealer prior to delivery of new vehicle. While performing research on this vehicle for another issue, NHTSA's stite provided an unrepaired recall on the vehicle in question. Upon further research, Volvo was aware of this issue and had already reported it to NHTSA prior to the date of vehicle delivery. See attached.

I am writing to file a formal safety complaint regarding my Volvo EX90, which experienced a complete and dangerous shutdown while driving on a LA freeway on Christmas Day. While traveling at freeway speed, the vehicle suddenly lost power and displayed a warning stating “Critical Electrical Fault.” The car shut down in the middle of active traffic. Two vehicles narrowly avoided colliding with us, and we were extremely fortunate to be able to turn the car back on, maneuver the vehicle to the shoulder of the road before being struck. The vehicle had to be towed from the shoulder of the freeway. This incident posed a serious risk of severe injury or death, not only to my passengers but also to other motorists. This was not an isolated incident. This is the second time this vehicle has experienced a sudden shutdown. The first incident involved a warning reading “Critical Propulsion Fault,” which also resulted in loss of vehicle function. Following the Christmas Day incident, the vehicle has been at an authorized Volvo dealership for over three weeks. As of today, Volvo has been unable to identify the root cause or provide a clear explanation or repair. The uncertainty surrounding the failure of a brand-new vehicle (1,754 Miles) further reinforces the seriousness of this defect. A vehicle that can unexpectedly lose all power at freeway speeds is fundamentally unsafe. Based on my experience, I believe the Volvo EX90 presents a significant safety defect, and I am deeply concerned that these vehicles continue to be sold and driven on public roads. I respectfully request that NHTSA investigate this matter to determine whether a broader defect or pattern exists and to take appropriate action to protect the public.

While driving on I-5 north by Castaic (exit 176A) the car displayed "electric system temporarily limited" then "critical electric fault" at which time it rapidly decelerated while on the freeway. The hazard lights were pressed but did not work. There was no shoulder and cars nearly rear ended our vehicle, with our family of 4 (including 2 kids) inside. We were able to navigate the vehicle to a small shoulder at the freeway exit and called CHP for support to ensure our safety while we seemed roadside assistance. Volvo roadside assistance contacted a tow truck and walked us through a "hard reset" of the vehicle. After about 15 minutes we were able to drive the car with a CHP escort off the freeway ramp to a nearby parking lot. The "electrical system temporarily limited" fault remained. Our car was towed to the nearest dealership where the fault was observed. At this point (8 calendar days later) no fix has been identified. This vehicle has had repeated electrical system faults since we leased in on 9/5/25 and has been serviced 3 previous times. This was the first time it stopped while driving.

I have been in multiple situation where my car is unable to charge from my home charger, and the issue is always same which is the need of GHCA replacement. Right now, GHCA for EX90 is in national back order with unknown ETA