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XC40 2022 Recharge Ultimate - Propulsion System Service Urgent

21K views 77 replies 31 participants last post by  takerhandy 
#1 ·
This all started last week.

Quick backstory, I bought my 2022 Recharge Ultimate at the beginning of October 2021. I have just under 2000 miles on it when I got the "Propulsion System Service Urgent drive to workshop" warning. The car had been sitting for 6 days since I went out of town for a bit for the holidays. As soon as I started driving was when the warning light came on. I drove to the closest Volvo dealer where they kept the car to run some tests and update some software that's not part of the OTA updates.

I picked up the car the next day the dealer was open. When I picked it up, they said everything looked good. I didn't even get to leave the parking lot when I got the same warning, along with turtle mode limiting power. The limit was very low, by the way.

Now, I have a loaner and the car has been back at the Volvo all this week. I had to call to get an update today. The service tech on the phone mentioned that the Volvo engineers have told them that there's an issue with the battery. The next steps are the battery is coming out of the car tomorrow and that they need to run more tests on the battery once it's out of the car.

So... this doesn't seem great on a car with less than 2000 miles...

I'll let you all know when I get another update.

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#3 ·
Oh wow, that's a terrible story. I just got my 2022 XC40 Recharge Ultimate last week. I'll keep my fingers crossed that the service folks can get it sorted out and returned to you quickly! 🤞
 
#4 ·
This all started last week.

Quick backstory, I bought my 2022 Recharge Ultimate at the beginning of October 2021. I have just under 2000 miles on it when I got the "Propulsion System Service Urgent drive to workshop" warning. The car had been sitting for 6 days since I went out of town for a bit for the holidays. As soon as I started driving was when the warning light came on. I drove to the closest Volvo dealer where they kept the car to run some tests and update some software that's not part of the OTA updates.

I picked up the car the next day the dealer was open. When I picked it up, they said everything looked good. I didn't even get to leave the parking lot when I got the same warning, along with turtle mode limiting power. The limit was very low, by the way.

Now, I have a loaner and the car has been back at the Volvo all this week. I had to call to get an update today. The service tech on the phone mentioned that the Volvo engineers have told them that there's an issue with the battery. The next steps are the battery is coming out of the car tomorrow and that they need to run more tests on the battery once it's out of the car.

So... this doesn't seem great on a car with less than 2000 miles...

I'll let you all know when I get another update.

View attachment 2284
We have the same problem, see my old post:
 
#9 ·
So you had a warning which sounds horrific. Others have ignored it and it went away. Being sensible you drove to Volvo with a seemingly fully functional car (with a scary message).

They fiddled with. Announced it fixed then before you could even leave you got the same message along with minimal power. Now they want to drop the battery …

Almost seems like their fiddling broke stuff.
Did they even test drive it?

From now on I think we need to note the odometer when we take it in. See if they actually test drive the cars they say are fixed.

I would definitely contact Volvo big brother and let them know especially if the technicians broke your car.

I wonder if there are spare batteries in america yet?

Good luck. That sounds absolutely horrible.
 
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#10 ·
That's pretty much what happened haha. To clarify, when the light first came on, I did run two quick errands since the car was pretty much running normally other than the warning light coming on. So the car did power cycle a few times before I brought it to the dealer. The warning did come on every time.

I first dropped the car off at Volvo on a Friday morning. They ran some tests and updated some kind of software, but I couldn't pick the car up that day, so it sat until Monday morning, which was the next day they were open because of New Years.

As soon as I got in the car and put it in drive, I got the warning again with the addition of turtle mode.

So I left the vehicle at the dealer on Monday and it's been there since. I was told I should be getting an update today, so I'll let you all know what I hear then.
 
#11 ·
Update time.

The Volvo dealer called me to give to let me know what's going on with my car. They were pretty vague on the details, which makes me want to talk to the actual tech and not the guy that makes the phone calls.

I was told that there is an issue - but it's not the high voltage battery pack itself, but a node or module related to the drive system? Does that make any sense to anyone here? Because it doesn't make that much sense to me. It just sounds a bit evasive instead of being an explanation.

Anyway, here's the really bad news. The part needed (whatever it actually is) is on back-ordered and will have to be shipped from Sweden when it's in stock. I was told that it would probably be two weeks best case scenario, but don't be surprised if it's longer.

Welp, I guess I'll be driving the loaner for the next couple of weeks on top of the week that I've already had it.

It seems like it might be a while before I have another update, but I have a feeling I'll end up in CA lemon law territory before my car is repaired.

I'll let you all know if I hear anything else.
 
#16 ·
Have the service manger get the regional Volvo rep involved. Depending on the rep if it drags on they may be willing to swap the car. You can read my posts on IHU and brakes and Volvo offered to swap car which I eventually am taking them up on it when my C40 comes in.Having the records and time out of service I have a backup plan to invoke lemon law if I change me mind.
 
#12 ·
TCAM is referred to as a "control module" in the part department. It Is a part of the VCM, or vehicle connectivity module.

I would ask if the module is the TCAM or VCM.

From recent conversations with my dealer, they have information on three local XC40 recharges with Shark fin antenna problems. This would explain the sudden backorder on the TCAM.
 
#13 ·
TCAM is referred to as a "control module" in the part department. It Is a part of the VCM, or vehicle connectivity module.

I would ask if the module is the TCAM or VCM.

From recent conversations with my dealer, they have information on three local XC40 recharges with Shark fin antenna problems. This would explain the sudden backorder on the TCAM.
Yeah, apparently the TCAM has a backup battery (BUB), which if it fails renders the car undrivable.

My dealer says mine is the 2nd Recharge they've had with a dead TCAM/TCAM BUB just now. Mine is now on week 6(!) waiting for the replacement from Europe to wind to Seattle.
 
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#17 ·
I short update for everyone.

I was curious, so I called the Volvo dealership today to try and get some clarification on what parts where needed to repair my car. There was a list of 14-15 parts, but I was told the main part needed was called a "CVTN" unit. The tech in charge of my repair isn't in today, but they're going to call me tomorrow with more information.

So this does not appear to be related to the TCAM issue that many other people are having.
 
#18 ·
I short update for everyone.

I was curious, so I called the Volvo dealership today to try and get some clarification on what parts where needed to repair my car. There was a list of 14-15 parts, but I was told the main part needed was called a "CVTN" unit. The tech in charge of my repair isn't in today, but they're going to call me tomorrow with more information.

So this does not appear to be related to the TCAM issue that many other people are having.
I found a definition for "CVTN" in a Volvo warranty for a hybrid model, apparently it stands for "Combined Voltage & Temperature Node", which sounds like maybe it's a sensor that measures battery voltage and temperature.
 
#20 ·
Another non-update haha.

The CVTN sensor/module has been replaced and supposedly the voltage readings are normal. The dealership is still waiting on the specialized tools to needed re-assemble the battery pack. They're hoping to have it put back together by the end of this week. It doesn't give me a ton of confidence that the dealership doesn't have the tools, because that also means they've never done this before either.

Volvo corporate has also reached out asking for a copy of my purchase agreement. They didn't say why they wanted it though.

I'll update again once I hear something.
 
#53 ·
The dealership is still waiting on the specialized tools to needed re-assemble the battery pack.
To replace the CVTN sensor the entire battery pack had to be opened up
The battery cover is a one time use part.
The service manager made a point to say this is the first car they've needed to make a repair to the battery back itself in the year or so this model has been out.
@ericksonpost - have you had any more problems with the high voltage battery pack since you had these repairs done? I'm going through what I am pretty sure is the exact same thing you went through. Same deal with specialist tools needed to open the battery and the dealership saying they've never had to do this before.

I'm just wondering if since the battery was resealed - it has been good without problems, or if you have had more trouble (apart from the TCAM issues)?
 
#22 ·
Update time.

My car is still at the dealership and I believe they're supposed to start working on it (again) today. It's also passed 30 days, which in CA qualifies the car as a lemon. Which is also why I think Volvo corporate reached out to me today and offered two things:

1) I can accept the total of 4 monthly payments.

or

2) They can buy the car back, but they haven't told me any details on what I'd be getting back for the car. Though in CA there's a lot of things the car manufactures are required to pay back. This process is also expeced to take 6-8 weeks and I believe I'm allowed to use the car for that time.

This is somewhat complicated since inventory is extremely low right now on pretty much every EV. So if I go the buy back route, I'm not sure if I'll be able to get another car in a reasonable time frame for a reasonable price. I also bought the XC40 while they were running a finance deal, so I have a good rate, which I probably won't get again if I need to get a new loan.

I was really hoping they would swap out the car since that would be the easiest for me. I've already applies for the CA rebates which would now need to be cancelled and/or changed.

Any thoughts?
 
#23 ·
Tell them to swap it. In GA there is a formula based on miles driven at time of first repair. As for what to do, how much do you like the car? What amazes me is I have never seen any brand buy back and swap so many cars, makes me wonder. For me that had given me 2 payments and are swapping car for a C40 due in about a month.
 
#29 ·
I think it depends on the state laws. I expect to lose the $250 tinting and $1400 Ceramic coating I did, but they gave me 2 car payments and a $750 gift card so I am still ahead. I believe some state's lemon laws allows you to recoup some cost items for the car. Also since we are in 2022 if they buy it back you still get $7500 incentive for 2021. Even on a swap I am trying to figure out if I get a second incentive as they are in theory I am trading my car in (Volvo makes up the difference to the dealer) and I am getting a new car. Trying to figure out if that is handled as a new purchases or not. I think a lot will depend on whether I need to get new financing, if so then I suspect I get another incentive.
 
#30 ·
I didn't spend much if anything on extras. I think what I may end up doing is asking if accepting the 4 months worth of payments still allows me to lemon the car if more issues arise.

I still haven't heard anything from the dealership either on the status of the repair. If the repair is successful, it might be worth it to take the money as long as nothing else comes up that puts the car in for major repairs again. If I hear the repair wasn't successful, I really feel like my only option is to have them buy back the car. I'll definitely push hard to swap, but I'll take my money back and try something else if it comes down to it.
 
#32 · (Edited)
I went by the dealership today to check in on my car since I hadn't received an updated in a while. The good news is that my repair is almost done. I should have it back by Friday or Saturday.

Even though it's almost fixed, I'm really leaning towards just getting my money back now. To replace the CVTN sensor the entire battery pack had to be opened up and was sitting in a shop for weeks exposed while the new cover came in. The first battery cover was damaged in shipping, so Volvo had to send a second cover, which is one reason things took so long. If you're curios, here's what the battery cover looks like:

Motor vehicle Automotive tire Wood Automotive exterior Bumper


The battery cover is a one time use part. If you zoom in, you can see where it needed to be pried open along the edges. Once this is re-assembled, it gets vacuumed sealed shut. This is why I'm a little hesitant to keep the car. I don't feel great that something that needs to be vacuumed sealed, was out open for so long.

The service manager made a point to say this is the first car they've needed to make a repair to the battery back itself in the year or so this model has been out. The service manager also mentioned that they've done a lot of TCAM repairs though...

That's all for now. I'll let you all know how things are when I get the car back.
 
#34 ·
I went by the dealership today to check in on my car since I hadn't received an updated in a while. The good news is that my repair is almost done. I should have it back by Friday or Saturday.

Even though it's almost fixed, I'm really leaning towards just getting my money back now. To replace the CVTN sensor the entire battery pack had to be opened up and was sitting in a shop for weeks exposed while the new cover came in. The first battery cover was damaged in shipping, so Volvo had to send a second cover, which is one reason things took so long. If you're curios, here's what the battery cover looks like:

View attachment 2506

The battery cover is a one time use part. If you zoom in, you can see where it needed to be pried open along the edges. Once this is re-assembled, it gets vacuumed sealed shut. This is why I'm a little hesitant to keep the car. I don't feel great that something that needs to be vacuumed sealed was out open for so long.

The service manager mad a point to say this is the first car they've needed to make a repair to the battery back itself in the year or so this model has been out. The service manager also mentioned that they've done a lot of TCAM repairs though...

That's all for now. I'll let you all know how this are when I get the car back.
Can’t speak to other brands, but it seems like Volvo did not expect anyone to be in the battery pack. Makes me rethink my swap to a C40. I get every forum is full of this stuff, but to swap and buy back so many year 1 cars makes me wonder.
 
#37 ·
Alas it is hard to tell whether these issues are rare or common. Early on their were IHU issues. They got fixed. Now we have tcam issues.

What percentage is the question and that is a question that we have no insight into.

We know that some cars do have tcam issues.
We know some cars have fin leaks leading to tcam issues
We know some cars have 12 volt battery issues

Alas we do know that service centers are often not able to rapidly fix these problems and that they are learning how to fix them and are hindered by getting parts from Europe. That coupled with a lack of loaners is impacting folks.

I love my P8. If it got stolen I would buy another. I might be a little stressed until I was sure it was one of the good ones (which mine is).

Cars having problems is not new. There was a huge recall of cars recently due to their abs systems causing them to catch fire including after driving! As in another do not put the car in the garage deal. (This was not Volvo).

I expect the tcam issues will get resolved like the IHU issues were when I do not know.

Good luck with the choices.
Life was easier when we did not have boards to here those with problems discuss. Alternatively it allowed us to buy flawed products without knowing.

One step forward one step back.
 
#40 ·
After calling around to quite a few dealerships - both Volvo and Hyundai (for an Ioniq 5), I'm going to have to keep the car. As much as I'd like to get rid of it at the moment...

There just isn't anything equivalent available right now.

I'm going to get the check worth 4 monthly payments and hope nothing else happens for the time being. Though in the short time I've had the car back, I have had three LTE/GPS dropouts, but at least they only lasted 5 minutes or so. Which is still not great when you need to know where to go in the LA area haha.

I'll let you all know if anything else happens releated to the main battery pack though.
 
#42 ·
AS long as they do not make you sign or acknowledge the 4 payments is in lieu of a lemon law claim, take the money and in a few months re-evaluate and get a lemon law attorney. You have 12 months usually to file a lemon law case.
 
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