As the author of this Web site I will add my comments, which I have printed in blue. 
Don Willson

Comments on the Final Summary Report:

I think I can speak for the thousands of VEXED Warriors when I say, "I (we) am(are) sorely disappointed in the wording and conclusions expressed in this final summary report." In no place did Volvo admit that there was any safety related problem. They maintain that there are minor problems with the throttle and the throttle software which cleaning and software upgrade will fix. It seems that they are issuing this recall to save them the expense of replacing electronic throttle modules that do not need replacing. I (we) know that ALL ETMs will fail due to the wearing out of the resistance element in the throttle position sensor, a carbon filled paint stripe applied to a  piece of flexible plastic film.

NHTSA has documented almost 4 (3.891) safety related incidents per thousand vehicle reports. While Volvo says, "Volvo indicated that this (vehicles going into limp home mode without need) was the most severe consequence of an ETM fault." I I think this is a case were the problem occurred to some other person. If it had happened to a Volvo executive or his spouse or his child, he would have a different additude, however, he/she would have just checked out another vehicle from the car pool.

(Note: the following NHTSA report has been reformatted to enhance the readability (Their report was in all caps and no paragraphs) but the text is all there.)) 

Report Date : December 22, 2006 at 12:28 PM NHTSA Action Number : EA05021

 

NHTSA Action Number : EA05021 NHTSA Recall Campaign Number : 06V441000 Make / Models :         Model/Build Years:          VOLVO / 780     1999      VOLVO / 850     1999      VOLVO / C70     1999-2001      VOLVO / C70 CONVERTIBLE     1999-2001      VOLVO / S60     1999-2002      VOLVO / S70     1999-2000      VOLVO / S80     1999-2001      VOLVO / S90     1999      VOLVO / V70     1999-2002      VOLVO / V70XC     1999-2001      VOLVO / V90     1999      VOLVO / VOLVO     1999-2001      VOLVO / X70     1999      VOLVO / XC70     2001 Manufacturer : VOLVO CARS OF N.A. LLC. (Note: I thought the cars were made by Volvo Cars Corporation in Sweden with VCNA being the US distributor) Component : VEHICLE SPEED CONTROL (Note: yes, if the throttle does not work then if does affect the speed but most people would think this means the cruise control) Date Investigation Opened : December 6, 2005 Date Investigation Closed : December 12, 2006

Summary:

On November 14, 2006 Volvo submitted a defect information report to NHTSA concerning ETM (Note: the definition of ETM is never mentioned.) failures in Model year (MY) 1999 through 2001 VOLVO models (not including the S40 and V40), MY 2002 S60 and with naturally aspirated engines and MY 2002 V70s. According to Volvo "A combination of throttle positioning sensor irregularities (Note: read FAILURE), a dirty throttle housing and/or inefficient software calibration may cause a warning lamp to light and the subsequent onset of limp home modes. (Note: they never mention the wearing out of the throttle position sensor.)

 

Subsequent onset of limp home modes, Volvo further stated that, "This resulted in a high number of these vehicles going into limp home mode without need." (Note: Volvo claims that ETMs were being replaced unnecessarily, just a very few in my opinion, and do not mention all of the driveability problems before a code is set and the ETM will be replaced under the 10-year, 200,000 mile warranty) Volvo indicated that this was the most severe consequence of an ETM fault in the subject vehicles. (Note: what about all of the crashes listed below.) The recall remedy is a software upgrade introduced by Volvo on March 16, 2006 in a costumer satisfaction program. At the time of the notification, 161,202 vehicles of the population of 331,301 had already had the software uploaded and were therefore not included in the population count of the recall.  

ODI'S analysis of complaints to ODI and Volvo, Volvo field reports and warranty data found that ETM failure could result in

(1)   engine stall;

(2)   mechanical limp mode;

(3)   lunging forward during low speed driving maneuvers; and

(4)   faltering during high speed merges or when crossing traffic.

(Note:  NHTSA demanded copies of the customer repair reports and NHTSA looked at thousands of pages to compile the data) 

ODI identified 12 crashes related to ETM failure, with:
·        6 caused by lunging incidents,

·        3 caused by stalling incidents,

·        2 caused by mechanical limp mode and

·        1 from the faltering condition.

 ODI’s analysis of complaint data and information obtained from consumer interviews identified:

·        1,289 incidents with safety related consequences (389.1 per 100,000 vehicles)

·        479 involving engine stall  (144.6 per 100,000 vehicles) and

·        729 involving mechanical limp mode (220.0 per 100,000 vehicles).

ODI's analysis of warranty claim narrative text shows at least 14,965 warranty claims with codes indicating and ETM fault resulting in vehicle operation in mechanical limp mode (4.5% of the subject vehicles). 

 Volvo’s recall addresses ODI'S safety concerns with ETM failures.  ODI will continue to monitor the subject vehicles to determine if additional action is required.  

This engineering analysis is closed.