NHTSA Complaint #10500856 — 2004 VOLVO XC90

TODAY, WE LEARNED OUR VOLVO XC90'S YAW RATE SENSOR HAS FAILED. THE ROOT CAUSE WAS WATER LEAKING INTO THE PASSENGER SIDE OF THE CAR DUE TO BLOCKED MOONROOF (I.E. SUNROOF) DRAINS, WHICH SHORTED THE YAW RATE SENSOR. THIS IMPAIRED THE ELECTRONIC STABILITY CONTROL AND BRAKES OF OUR VOLVO, PUTTING US AT RISK OF ACCIDENT. RESEARCH SHOWS THIS IS A FREQUENT AND RECURRING PROBLEM KNOWN SINCE AT LEAST 2004. IT HAS CAUSED THOUSANDS OF DOLLARS IN DAMAGE TO NUMEROUS XC90S. VOLVO IS AWARE OF THIS ISSUE UP TO AND INCLUDING THE PRESIDENT OF VOLVO USA. EVEN THOUGH EASY AND INEXPENSIVE REGULAR MAINTENANCE WOULD PREVENT EXPENSIVE DAMAGE, NEITHER THE VOLVO USER MANUAL NOR MAINTENANCE SERVICE OPERATIONS GUIDES MENTION THE NEED. THE DAMAGE WE AND OTHERS HAVE SUFFERED WAS COMPLETELY PREVENTABLE. THE ROOT CAUSE IS A DESIGN DEFECT, WHICH VOLVO SERVICE PROVIDERS REGULARLY CORRECT BY CUTTING THE BOTTOM END OF THE HOSES. A SERVICE PROVIDER IS REPORTED AS SAYING, "THIS IS A BAD DESIGN. WE DON'T KNOW WHY VOLVO DESIGNED IT THIS WAY, SO WE JUST CUT OFF THE BOTTOM TWO INCHES OF THE HOSES." GIVEN THE RISK THIS DEFECT PUTS OWNERS AT AND VOLVO'S ONGOING FAILURE TO CORRECT THIS DESIGN DEFECT AND/OR NOTIFY OWNERS OF THIS ISSUE AND THE REQUIRED MAINTENANCE TO ADDRESS IT, I BELIEVE A RECALL OF ALL AFFECTED VOLVO XC90S IS WARRANTED AND SHOULD BE INSTITUTED IMMEDIATELY. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR