Volvo’s flagship electric SUV, the EX90, has been hailed as a key step forward in the brand’s transition to a fully electric future. However, its journey to market has been anything but effortless. Software-related challenges have repeatedly delayed production and deliveries, prompting Volvo to implement significant improvements for the 2026 model year. Unfortunately, the automaker is now facing another obstacle — a safety recall affecting the 2025 EX90 units already produced and sold in the United States.
According to a recall report issued by the National Highway Traffic Safety Administration (NHTSA) on September 30, 2025, the issue involves a potential defect in the vehicle’s power-operated tailgate. Specifically, Volvo has identified that the spindle nut within the tailgate drive unit can detach from the aluminum tube while the tailgate is open. Should this separation occur, the spindle could be released suddenly, allowing the tailgate to close abruptly and unexpectedly. This presents a possible injury risk to anyone standing near the rear of the vehicle. The problem was traced back to an error during parts handling at a supplier’s facility, where defective (“Not OK”) components were mistakenly mixed with acceptable (“OK”) ones during the assembly process.
The recall affects a total of 1,119 EX90 units built between April 22, 2024, and February 17, 2025. Volvo’s internal investigation began in March 2025 after receiving a report of a tailgate spindle detachment from the field. A second similar event occurred a month later during in-house testing, confirming that the issue was not an isolated case. Once the pattern became clear, the company conducted a deeper inquiry, which ultimately led to the current recall campaign.
Starting November 18, owners of affected vehicles will receive official recall notifications. Authorized Volvo dealerships will replace both tailgate drive units at no cost to customers. To ensure that such mishaps don’t occur again, Volvo’s supplier has since overhauled its quality assurance system. The new protocol introduces an automated robotic process to sort rejected components into a secured container, preventing any possibility of mixing faulty parts with functional ones.
Despite this setback, Volvo continues to make strides with the EX90’s development. The upcoming 2026 version will feature a cutting-edge 800-volt electrical architecture supporting up to 350 kW charging—an impressive leap from the current model’s 250 kW capability. This improvement not only promises significantly faster charging times but also enhances overall performance and energy efficiency. Combined with ongoing software refinements, Volvo aims to deliver a smoother, more reliable ownership experience.
While the recall represents a temporary bump in the road, Volvo’s proactive response and forthcoming upgrades signal its commitment to maintaining safety and pushing the boundaries of its electric vehicle technology. With these refinements in place, the EX90 is expected to regain momentum and solidify its position as one of the most advanced and family-friendly electric SUVs in its class.