Loss of brake function: Volvo recalls over 14,000 EVs and PHEVs in the US

Volvo has issued a recall for 14,014 electric and plug-in hybrid vehicles in the United States due to a critical braking issue caused by a software malfunction. Volvo has urged EV and PHEV drivers to avoid ‘One Pedal’ and ‘B’ modes until the software has been updated.

Vehicles affected by the software issue may not be able to brake under specific driving conditions, particularly when using regenerative braking modes central to electric mobility systems. The fault stems from software version 3.5.14 installed in certain 2020–2026 model year vehicles, which can disable braking entirely if a driver coasts downhill in ‘B’ mode (for plug-in hybrid vehicles) or One Pedal Drive mode (for pure electric vehicles) for more than 100 seconds without touching either pedal. This affects both the Brake Control Module and overall driveability—directly challenging one of the core UX features of modern EVs.

In a statement to InsideEVs, a Volvo spokesperson advised: “We are asking customers who have not yet had the corrective software installed in their car to avoid selecting ‘B’ mode or One Pedal Drive while driving.”

Models impacted include “certain” 2023 Volvo C40 BEV, 2025 EC40, 2023-2024 XC40 BEV, 2020-2026 XC90 PHEV, 2022-2026 XC60 PHEV, 2023-2025 S60 PHEV, 2024-2025 V60 PHEV, and 2025-2026 EX40 and 2025 S90 PHEV. The problem appears isolated to a dealership-installed software version that was not available over-the-air. Volvo has since issued a corrected version, 3.6.4, which began rolling out on 16 June via OTA and in retailers’ workshops.

“The brake module software will be updated over-the-air (OTA) or by a dealer, free of charge. Owner notification letters are expected to be mailed August 6, 2025,” the recall notice on the website of the National Highway Traffic Safety Administration (NHTSA) states.

The flawed software version 3.5.14 was released in April and contained other enhancements unrelated to braking, including changes to the lane keeping assist, tyre pressure monitoring, and road sign recognition systems. However, no detailed chronology has been published by Volvo on how the braking issue passed internal safety checks.

This latest incident follows a separate recall earlier in the year involving roughly 7,500 PHEVs due to defective high-voltage battery cells that posed a fire risk. The affected models included 2020–2022 PHEVs across the same model range.

Leadership changes at Volvo in April, with Håkan Samuelsson returning to an executive role following Jim Rowan’s departure, signal the company’s intent to regain strategic focus amid first-quarter sales setbacks. Despite strong EV ambitions and record results in 2024, the brand has struggled to maintain momentum into 2025, with quality issues and shifting consumer sentiment adding pressure.

nhtsa.gov (recall; PDF), insideevs.com