NHTSA Complaint #11463566 — 2017 VOLVO XC90

The air suspension dust covers on the rear air springs were originally installed from the factory using substandard plastic zip ties that are known to slip off. This is a known design flaw and is even documented by Volvo via technical journal and reported to the NHTSA as follows. NHTSA ID Number: 10158664 Manufacturer Communication Number: TJ30517.6.0-2019 All vehicles with this design flaw are at risk failure of the rear air springs. The manufacturer has taken a wait and see approach to pass on the cost of repairs to customers. One of the air springs was found to have its dust cover slip off and was confirmed by a Volvo dealer. This was caused due to use of plastic zip ties rather than crimped metal straps which have been used as a repair documented by the manufacturer and used in newer version of the air springs. The cost of repair for each spring affected is $1300-1500 and at the time of repair the require that the unaffected air spring be remediated with a metal strap to prevent failure which could lead to unexpected and catastrophic air spring collapse. I obtained two quotes from two Volvo dealers. Volvo has already voluntarily extended the warranty on another associated component for their air suspension system which they know to have a manufacturing flaw. This air spring design flaw should also be included or added as a separate voluntary or mandatory campaign. Fortunately, I noticed this failure while replacing winter tires for summer tires and was able to preemptively get this assessed by my servicing dealer. They explained the severity of the issue and recommended as per Volvo's Technical Journal to replace the entire air spring as it was compromised due to road debris exposure from having its dust cover drop. A component failure due to an inappropriate restraint being used to retain a safety shield around the air spring could lead to loss of control.