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My XC-40 developed a vibration under braking at highway speeds (above 45 mph) after about 9,000 miles. About half the miles on this car include mountain driving (I live in Colorado). The dealer replaced both front rotors under warranty: problem fixed, for now. I am wondering if this was a one-off issue or if this is a design flaw: are the brake rotors sturdy enough for extended mountain driving? I noticed when I use cruise control to maintain speed on long downhills, engine braking is often insufficient to maintain speed and is supplemented with extended automatic light appliaction of the brakes. I am wondering if this generates too much heat in the brakes and is part of the issue. Will post in this forum if the problem reappears. Has anyone else experienced this?
 

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Front rotors warped and replaced under warranty at 11k miles. Vibration when braking gone for now. My theory is the rotors are too small for the dynamics and weight of the vehicle. Small when compared to my GT350 rotors...
 

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Yes, mine were warped by 25k miles and replaced under warranty x 4. I still have vibration apparently from tire wear. Dealer is taking the approach that "it's just the tires" and doesn't seem to understand that something has caused the problematic tire wear.
 

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Brakes on mine have been vibrating since 8,000 miles. Volvo just replaced them today at 14,000 miles. Said this was a known issue. They are wearable item but malfunctioning at this few miles is a problem. After finding out they won’t cover a leather seat issue, I’m ready to move on from Volvo.
 

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My problem was at 24.000 miles. My rear brake pads warped completly. I drive always in highway with another person in the car and no luggage. Volvo told me that is normal because of stability control, but i was happy wtih this information.
 

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My XC-40 developed a vibration under braking at highway speeds (above 45 mph) after about 9,000 miles. About half the miles on this car include mountain driving (I live in Colorado). The dealer replaced both front rotors under warranty: problem fixed, for now. I am wondering if this was a one-off issue or if this is a design flaw: are the brake rotors sturdy enough for extended mountain driving? I noticed when I use cruise control to maintain speed on long downhills, engine braking is often insufficient to maintain speed and is supplemented with extended automatic light appliaction of the brakes. I am wondering if this generates too much heat in the brakes and is part of the issue. Will post in this forum if the problem reappears. Has anyone else experienced this?
I had issues at 6k on a 2021 T5, all highway miles around the Boston area. Dealer replaced the front rotors under warranty. Break pads are fine and didn’t need replacement. This just doesn’t feel right. There is a bigger issue here in my mind.
 

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I had issues at 6k on a 2021 T5, all highway miles around the Boston area. Dealer replaced the front rotors under warranty. Break pads are fine and didn’t need replacement. This just doesn’t feel right. There is a bigger issue here in my mind.
I own a 2019 XC40 T5 bought new. The brakes were replaced under warranty at 9k and again at 20k and at 24k they are warped again. I also use cruise control a lot and I do a lot of highway driving. Just for reference my last car was a mini copper didn't need to replace the brakes until 50k miles and I drove the same way.
 

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My XC-40 developed a vibration under braking at highway speeds (above 45 mph) after about 9,000 miles. About half the miles on this car include mountain driving (I live in Colorado). The dealer replaced both front rotors under warranty: problem fixed, for now. I am wondering if this was a one-off issue or if this is a design flaw: are the brake rotors sturdy enough for extended mountain driving? I noticed when I use cruise control to maintain speed on long downhills, engine braking is often insufficient to maintain speed and is supplemented with extended automatic light appliaction of the brakes. I am wondering if this generates too much heat in the brakes and is part of the issue. Will post in this forum if the problem reappears. Has anyone else experienced this?

Here is my repair history. SO frustrated. The Aug. repair cost me 1500.00 Has anyone had luck with Corporate

service history 2019 XC 40 picked up in Sweden with OSD
11/22/19- 6,731mi- rear rotors replaced
12/16/19- 8,310 mi- front rotors replaced
12/4/20- 32,792 mi- front rotors replaced
8/3/21 - 45,792mi- front and rear pads and rotors replaced
 

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My XC-40 developed a vibration under braking at highway speeds (above 45 mph) after about 9,000 miles. About half the miles on this car include mountain driving (I live in Colorado). The dealer replaced both front rotors under warranty: problem fixed, for now. I am wondering if this was a one-off issue or if this is a design flaw: are the brake rotors sturdy enough for extended mountain driving? I noticed when I use cruise control to maintain speed on long downhills, engine braking is often insufficient to maintain speed and is supplemented with extended automatic light appliaction of the brakes. I am wondering if this generates too much heat in the brakes and is part of the issue. Will post in this forum if the problem reappears. Has anyone else experienced this?
Here is my repair history. SO frustrated. The Aug. repair cost me 1500.00 Has anyone had luck with Corporate

service history 2019 XC 40 picked up in Sweden with OSD
11/22/19- 6,731mi- rear rotors replaced
12/16/19- 8,310 mi- front rotors replaced
12/4/20- 32,792 mi- front rotors replaced
8/3/21 - 45,792mi- front and rear pads and rotors replaced
I posted here before but want to give an update. I bought my xc40 brand new in 2019. Vovlo replaced my rotors at 10k miles and again at 18k mile and by the time I hit 24k the vibration and thumping was back. I just wanted this fix once and for all and I researched getting high performance rotors. I paid a local garage to put them in because Volvo said they could not install anything but vovlo parts. Has been 4 months now without any vibration and no warping. I'm really happy them. So let me give you some more detail. The two rotors were slotted and dimpled. They cost me $247 and $140 to get them installed. 322mm front rotors. Here is the very interesting some web sites don't a selection on size and what they'll send you is 345mm rotors. I know that from experience. From what I think I understand is that xc40 has four sets of brakes configurations. 296mm front with, 280mm, rear, What I have 322mm front with 302mm rears, and 345mm fronts with 302mm rears. When I purchased my car I got the standard tire. I hope this help. -Tim
 

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It isn't the rotors that are the problem. Volvo pad material choice (low noise) is poor and you get material transfer and then hot spots on the rotor. When mine start to pulsate I run up to 100mph and hard brake a couple times without engaging the ABS. This re-beds the pads and removes the high spots and the brake judder goes away in a couple days. If you use sloted and dimpled/drilled rotors that are the same size, al you are doing is reducing your brake surface area reducing braking capability. Use a better brake pad and most of your rotor problems will go away.
 

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I own a 2019 XC40 T5 bought new. The brakes were replaced under warranty at 9k and again at 20k and at 24k they are warped again. I also use cruise control a lot and I do a lot of highway driving. Just for reference my last car was a mini copper didn't need to replace the brakes until 50k miles and I drove the same way.
My XC-40 developed a vibration under braking at highway speeds (above 45 mph) after about 9,000 miles. About half the miles on this car include mountain driving (I live in Colorado). The dealer replaced both front rotors under warranty: problem fixed, for now. I am wondering if this was a one-off issue or if this is a design flaw: are the brake rotors sturdy enough for extended mountain driving? I noticed when I use cruise control to maintain speed on long downhills, engine braking is often insufficient to maintain speed and is supplemented with extended automatic light appliaction of the brakes. I am wondering if this generates too much heat in the brakes and is part of the issue. Will post in this forum if the problem reappears. Has anyone else experienced this?
I also have had my brakes replaced 5 times in less then a year. There is a constant pulsation that they fix under warranty then a few weeks to month I’m back at the shop again. I’m so tired of this issue. I actually contacted Volvo to help me get out of this car because clearly this is a bigger problem than they can fix, Volvo responded they cant help me at this time! ARE YOU SERIOUS! So now I’m seeking law assistance. This car for the price it is should not be having so many issues? Anyone else car to elaborate
 

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I posted here before but want to give an update. I bought my xc40 brand new in 2019. Vovlo replaced my rotors at 10k miles and again at 18k mile and by the time I hit 24k the vibration and thumping was back. I just wanted this fix once and for all and I researched getting high performance rotors. I paid a local garage to put them in because Volvo said they could not install anything but vovlo parts. Has been 4 months now without any vibration and no warping. I'm really happy them. So let me give you some more detail. The two rotors were slotted and dimpled. They cost me $247 and $140 to get them installed. 322mm front rotors. Here is the very interesting some web sites don't a selection on size and what they'll send you is 345mm rotors. I know that from experience. From what I think I understand is that xc40 has four sets of brakes configurations. 296mm front with, 280mm, rear, What I have 322mm front with 302mm rears, and 345mm fronts with 302mm rears. When I purchased my car I got the standard tire. I hope this help. -Tim
The rotor sizes you provided are helpful. Thank you. I am just about to put on my 1st replacement pads myself and I was seeing different rotor & pad sizes at O'Reilly's auto parts so, I was unsure what sizes I have. I measured my front rotors and found they are 322mm and my rear were ~300mm so this is in agreement with what you said. Any idea when they use one size vs. another? Isuspect R-Design vs. T4 vs. T5 get larger or smaller rotors. FYI - I have 20-in wheels on a T5 momentum.
 

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I'm dealing with this now - breaking coming off of highway speeds (or something around 40-45 mph) I get shuttering/shaking also feel it in the steering wheel. I know i've had rotors replaced once under warranty but I feel like this is the 2nd time I've been told they are rusting and need to be replaced at my expense. I have 40,000 miles on my car it's it's 4 years old. I feel like break/rotor issues are common on this car.
 

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I'm dealing with this now - breaking coming off of highway speeds (or something around 40-45 mph) I get shuttering/shaking also feel it in the steering wheel. I know i've had rotors replaced once under warranty but I feel like this is the 2nd time I've been told they are rusting and need to be replaced at my expense. I have 40,000 miles on my car it's it's 4 years old. I feel like break/rotor issues are common on this car.
I just had my rotors replaced under warranty as well. I wonder if they also replace the brake pads - if old pads were still being used with the new rotor, wouldn't the old pads create imperfections on the new rotors thereby generating the pulsing problem again? If they replace rotors, shouldn't they also replace pads?
 

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I just had my rotors replaced under warranty as well. I wonder if they also replace the brake pads - if old pads were still being used with the new rotor, wouldn't the old pads create imperfections on the new rotors thereby generating the pulsing problem again? If they replace rotors, shouldn't they also replace pads?
That's a good question. I was just looking at my report from my 40K service done 5 months ago, My front brake pads were at 6mm and ok but now at 2mm - with rusted rotors. I am having this repaired.

I replaced the rear brake pads back in February but the rear rotors are also now rusted and need to be replaced. If I have the rear rotors replaced, I guess i'll need new brake pads again?
 

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So does anybody have a link to some aftermarket rotors & pads they found success with?
I too had replaced warped rotors at 49k. They warped again 2 months later at 50k outside of warranty and the dealer wouldn't replace them. I was pissed.
 
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