2015 Volvo XC90 2.0L Diesel · PF65 FJA

A pattern of front suspension wear and brake disc corrosion stands out as the defining mechanical concern on this 2015 Volvo XC90, with the most recent test on 9 April 2026 capturing both issues in a single visit. On that date it failed with a Major defect for an excessively worn nearside front lower suspension arm ball joint, before being repaired and re-presented the same day to pass. That same inspection also flagged corroded front and rear brake discs and a corroded rear anti-roll bar as advisories, alongside minor defects on both front wiper blades. Earlier in the 2022 cycle the vehicle failed twice in quick succession, first on 7 December for inoperative door release mechanisms on the offside front and offside rear passenger doors, and then on 16 December for a non-functioning windscreen washer accompanied by a Dangerous failure for rear brake pads measuring less than 1.5 mm thick and an advisory for thinning front pads. The intervening tests in December 2023, December 2024 and May 2025 returned clean passes with no advisories recorded, so the 2026 outcome represents a noticeable deterioration rather than a continuing trend. With 94,103 miles recorded across eleven years, annual mileage averages around 8,555 miles, which sits squarely within normal expectations for a vehicle of this age and class. There are no extended absences from the testing record and no sudden jumps between readings, suggesting continuous use rather than long periods of standing. The single Dangerous brake pad finding in late 2022, however, indicates that braking consumables have at some point been left to wear to a critical level rather than being replaced at the normal service interval. Combined with the corrosion now appearing on both brake disc faces and the rear anti-roll bar, the evidence points to a chassis and braking package that is reaching the stage where surface corrosion and component wear are progressing simultaneously. For a prospective buyer, the priority items to scrutinise are the front suspension and braking components. The nearside front lower arm ball joint that was excessively worn in April 2026 should be confirmed as a new or known-good replacement, and the opposite arm should be inspected for similar play, as ball joints on this generation of XC90 are known to deteriorate progressively. On a test drive, listen for clonking or knocking from the front end over speed humps and uneven surfaces, and feel for vagueness or shudders through the steering wheel, particularly under braking. The advisory items on corroded front and rear brake discs warrant close visual inspection of the disc faces for heavy pitting or a pronounced lip, and any judder, vibration or pulsing through the brake pedal under firm application would suggest the discs have worn beyond their service limit. The corroded rear anti-roll bar should be checked visually for surface rust, and the anti-roll bar bushes and drop links should be inspected for cracking or splitting, as deteriorated bushes commonly produce a rattle or squeak when traversing undulating roads. Finally, confirm that both front wiper blades have been replaced and that the door release mechanisms on the offside front and rear, which failed in December 2022, are operating correctly from both inside and outside the vehicle, as intermittent interior door handle failures are a known weak point on this model.