Volvo EX40 1(EX40) — Problems & Common Faults
Weaknesses, engine ratings and buying advice
The EX40 is the name used since February 2024 for the former XC40 Recharge Pure Electric – as with its coupe sibling, Volvo simply swapped the badge as part of its electric naming overhaul, not the technology. Unlike the coupe-shaped EC40, the EX40 keeps the classic, boxy XC40 body, so the coupe's typical drawbacks such as limited all-round visibility or tight rear headroom do not apply here.
Since model year 2025 the drivetrain lineup matches the EC40 exactly: rear-wheel drive with 175 kW (67 kWh) or 185 kW in Extended Range guise (79 kWh), plus the 300 kW all-wheel-drive version and, since spring 2024, a software-unlocked Performance version with 325 kW. The extra 25 kW over the regular Twin Motor comes purely from the control software, chassis and brakes are untouched.
As with the EC40, Volvo used the renaming to switch the EX40's user interface to Google Automotive – the largest over-the-air update in company history. It largely fixed the dropouts in internet connectivity, navigation and traffic-sign recognition known from the predecessor models, but occasionally introduced small new display glitches.
From the mechanically identical XC40 Recharge, the EX40 inherits mainly the issues around the 12-volt auxiliary battery, which can discharge during extended standstill, and surface rust on the barely used mechanical brake discs caused by strong regenerative braking. A previously documented complete system shutdown caused by a software error in the predecessor's battery and drive control units also cannot be ruled out given identical hardware. For a used EX40, the same checks on update history and the 12-volt battery as for the XC40 Recharge are worthwhile.
Engine Overview
The Volvo EX40 1 is available with 4 engine variants — from 238 to 442 hp. 1 variants had engine changes — the model year is crucial.
Permanent-magnet synchronous motor on the front axle, fed by a front power inverter and a 78 kWh NMC pack (CMA platform, shared with Polestar 2 and C40). The motor and single-speed reduction gear themselves are robust and low-wear. The weak point is the high-voltage control side: the Battery Energy Control Module (BECM) can reset and disconnect the HV system, causing sudden loss of drive power — the subject of recall R10078. Separately, the front inverter shows up as a hardware failure ('Propulsion System Service Required'). The biggest everyday nuisance is the 12 V battery, which repeatedly drains due to a software-related parasitic load. Mechanically low-maintenance, but verify software and module levels before buying.
- !! Recall: BECM software — risk of sudden loss of drive power from 20,000 km
Volvo recalled over 2,000 XC40 Recharge vehicles in 2021 due to a software fault in the Battery Energy Control Module (BECM). Sudden complete loss of drive power while driving was possible.
- !! BECM/BDU hardware failure ('Propulsion System Service Required') from 60,000 km
Beyond the software recalls, the high-voltage control hardware (Battery Energy Control Module / Battery Disconnect Unit) on the CMA platform can also fail as hardware. 'Propulsion System Service Required' appears and the vehicle refuses to drive or only runs in limp mode.
Symptoms: 'Propulsion System Service Required' warning, reduced power or no drive, vehicle stranded. - !! Front inverter / e-motor failure from 70,000 km
The front power inverter is a known hardware weak point on the CMA platform (XC40 Recharge, C40, Polestar 2). Its failure triggers the 'Propulsion System' warning and can cause sudden, complete loss of drive power — safety-critical.
Symptoms: Sudden total loss of drive without warning, 'Propulsion System' warning, vehicle coasts to a stop.
+ 4 more engine weaknesses + vehicle weaknesses
Twin-motor all-wheel-drive variant with a permanent-magnet synchronous motor on each axle, fed by two inverters and the 78 kWh NMC pack (CMA platform, shared with Polestar 2 Dual Motor and C40). Both motors and reduction gears are robust with almost no mechanical wear. The typical problems are electronic: the Battery Energy Control Module (BECM) can reset and disconnect the high-voltage system — sudden loss of drive power, addressed by recall R10078. The front inverter shows up as a hardware failure ('Propulsion System Service Required'). A persistent nuisance is the repeatedly draining 12 V battery from software-related parasitic load. Before buying, check current software levels and recall completion.
- !! Recall: BECM software — risk of sudden loss of drive power from 20,000 km
Volvo recalled over 2,000 XC40 Recharge vehicles in 2021 due to a software fault in the Battery Energy Control Module (BECM). Sudden complete loss of drive power while driving was possible.
- !! BECM/BDU hardware failure ('Propulsion System Service Required') from 60,000 km
Beyond the software recalls, the high-voltage control hardware (Battery Energy Control Module / Battery Disconnect Unit) on the CMA platform can also fail as hardware. 'Propulsion System Service Required' appears and the vehicle refuses to drive or only runs in limp mode.
Symptoms: 'Propulsion System Service Required' warning, reduced power or no drive, vehicle stranded. - !! 12V battery drains during extended standstill
The XC40 Recharge can completely drain the 12V auxiliary battery within a week of standing. Volvo has released software updates; older vehicles should be brought up to the latest software version.
Symptoms: Car does not respond after standing time, no start possible, all systems dead
+ 1 more engine weaknesses + vehicle weaknesses
Vehicle Weaknesses
| Weakness | Cost | |
|---|---|---|
| Recall: no braking effect in One Pedal Drive mode In B mode or One Pedal Drive, no braking effect can be achieved via the brake pedal while coasting downhill. A software update fixes the issue; until then, use of the mode is discouraged. Symptoms: In One Pedal Drive the vehicle does not decelerate as expected downhill, the brake pedal feels ineffective. | Low | |
| Recall: reduced seatbelt restraint effectiveness A fault in the belt retractor system (torsion bar) can reduce the restraint effectiveness of the seatbelt. Affected belts are inspected and replaced if necessary. | Low | |
| Recall: rearview camera image fails to display in reverse A software error can cause the rearview camera image to fail to display when reverse gear is selected. An OTA or dealer software update fixes it free of charge. Symptoms: Rearview camera shows no image or a frozen image when reversing. | Low |
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Known Problems and Issues +
A total of 18 weaknesses have been documented for the Volvo EX40 1 (2024–2026) — 11 engine-related and 7 vehicle-related. Typical issues affect Other, Electronics, Brakes.
EX40 (Volvo-ERAD-XC40-SM, 2024–2026) — Be Careful: Recall: BECM software — risk of sudden loss of drive power, BECM/BDU hardware failure ('Propulsion System Service Required'), Front inverter / e-motor failure. Power: 238 PS.
EX40 (Volvo-ERAD-XC40-SM, 2024–2026) — Be Careful: Recall: BECM software — risk of sudden loss of drive power, BECM/BDU hardware failure ('Propulsion System Service Required'), Front inverter / e-motor failure. Power: 252 PS.
EX40 (Volvo-ERAD-XC40-TM, 2024–2026) — Be Careful: Recall: BECM software — risk of sudden loss of drive power, BECM/BDU hardware failure ('Propulsion System Service Required'), 12V battery drains during extended standstill. Power: 408 PS.
EX40 (Volvo-ERAD-XC40-TM, 2024–2026) — Be Careful: Recall: BECM software — risk of sudden loss of drive power, BECM/BDU hardware failure ('Propulsion System Service Required'), 12V battery drains during extended standstill. Power: 442 PS.
What to watch out for with the Volvo EX40? See the detailed listing of all engine and vehicle weaknesses in the sections above.
Frequently Asked Questions
What problems and weaknesses does the Volvo EX40 1 have? +
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Last updated: February 2026 · All information without guarantee