NHTSA Complaint #10443048 — 2005 VOLVO XC70

THE CAR WAS PARKED OVER NIGHT AT HOME. WHEN REVERSING THE CAR OUT OF THE GARAGE THE FOLLOWING MORNING A GRINDING NOISE WAS HEARD FROM THE LEFT FRONT WHEEL. ON INSPECTION IT WAS APPARENT THAT THE FRONT DRIVER'S SIDE HELICAL SUSPENSION SPRING HAD FRACTURED IN THE FIRST NINE INCHES OF ITS LOWER ARC. THE CAR WAS TOWED TO THE GARAGE AND THEY INFORMED ME THAT THE SPRING WAS IN CONTACT WITH THE TIRE AND THE SPRING RECESS IN THE TOP OF THE WHEEL ARCH. ON INSPECTION IT WAS APPARENT THAT THE SPRING HAD SUDDENLY FAILED DUE TO METAL FATIGUE AND THAT THE FRACTURED SURFACES WERE PARTIALLY RUSTED. THE CAR WAS SERVICED TWO WEEKS PRIOR TO THIS FAILURE AND NO PROBLEMS IN THE FRONT SUSPENSION OR WHEEL ALIGNMENT WERE NOTICED. I HAVE RETAINED THE SPRING FOR INSPECTION AND NOTED THAT THE POWDER COATING ON THE LOWER PART OF THE SPRING WAS MISSING AND THAT THE SPRING'S BARE METAL SURFACE WAS CORRODED. IF THE SPRING HAD FAILED WHILE DRIVING AT SPEED THE BROKEN END WOULD HAVE CAUSED A TIRE FAILURE WITH ACCOMPANYING LOSS OF CONTROL WITH SERIOUS INJURIES TO PASSENGERS OR DRIVER.