NHTSA Complaint #11666445 — 2025 VOLVO XC90

I am filing this report regarding a serious and potentially dangerous issue with my 2025 Volvo XC90 (VIN: [XXX]), purchased new on [XXX]. On [XXX], with only 4,516 miles, I experienced a sudden and unexplained drop in tire pressure while driving. I pulled over safely, replaced the flat with a temporary tire, and took it to a local tire shop. The technician informed me that the rear passenger-side rim had a severe internal crack on the inside barrel, causing an air leak. There was no visible damage to the tire, no pothole impact, no curb hit—only a clean break in the rim, which suggests a possible structural or manufacturing defect. I immediately brought the car to the original dealership (Volvo Cars Clear Lake in Friendswood, TX), where Service Advisor Jared Black dismissed my concern and refused to cover the repair under warranty, claiming the rim must have hit a rock. I disagreed and requested documentation of this finding, but Mr. Black initially refused to provide the inspection report. After persistent arguing and a 5-hour wait at the service center, I was finally given a report showing a $2,338.99 wheel replacement recommendation, not covered by warranty. I bought a Volvo for its safety reputation, but this rim cracked under normal driving conditions and low mileage. A failure like this at highway speeds could have been catastrophic. I believe this warrants an official safety investigation to determine whether other 2025 Volvo XC90 rims may be at risk of similar failure. Please investigate. I have documentation available and am willing to provide additional information. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)