2004 Volvo XC90 Problems, Complaints & Recalls

Source: NHTSA · Updated Mar 9, 2025 · 462 owner complaints analyzed

Compared with other XC90 years
Far more complaints than other years 1st of 23 for complaints
NHTSA crash rating
Not rated

Owners have filed 462 complaints with NHTSA about the 2004 Volvo XC90. That is the most of any XC90 model year in the database (23 years). The most reported problem area is electrical system (158 complaints, 34%), typically at around 94,500 miles. Complaints mention 9 crashes, 3 fires, 8 injuries. There are 6 safety recalls covering this model year. NHTSA has opened 3 defect investigations involving it.

Volvo XC90
2025 Volvo XC90 II in Stuttgart-Vaihingen. Representative photo; appearance varies by model year. Photo: Alexander Migl, CC BY-SA 4.0, via Wikimedia Commons.

Complaints are unverified owner reports and are not adjusted for sales volume.

Compare with another car

Most common 2004 Volvo XC90 problems

Complaints grouped by the part of the car owners reported, with the median mileage when the problem happened.

Electrical System158 · ~94,500 mi
Power Train145 · ~78,000 mi
Fuel System, Gasoline40 · ~75,000 mi
Fuel/propulsion System34 · ~137,000 mi
Exterior Lighting32 · ~104,500 mi
Air Bags31 · ~90,000 mi
Engine28 · ~104,789 mi
Engine and Engine Cooling24 · ~76,376 mi
Suspension23 · ~62,720 mi
Steering20 · ~70,000 mi
Problem areaComplaintsShareMedian milesOwners mention mostTypical repair cost
Electrical System problems15834%94,500“instrument panel” (11%)$1,750
Power Train problems14531%78,000“transmission service” (12%)$8,050
Fuel System, Gasoline409%75,000——
Fuel/propulsion System347%137,000——
Exterior Lighting327%104,500——
Air Bags317%90,000——
Engine286%104,789——
Engine and Engine Cooling245%76,376——
Suspension235%62,720——
Steering204%70,000——
Vehicle Speed Control174%113,026——
Unknown or Other153%101,000——
Structure143%99,608——
Electronic Stability Control (esc)112%122,578——
Service Brakes102%125,000——
Wheels102%65,098——
Service Brakes, Hydraulic72%72,000——
Equipment61%43,200——
Seat Belts61%88,380——
Tires61%49,500——
Visibility51%130,000——
Latches/locks/linkages41%46,200——
Fuel System, Other20%79,230——
Seats20%92,500——
Visibility/wiper20%108,500——
Child Seat10%———
Forward Collision Avoidance10%———
Fuel System, Diesel10%54,000——
Interior Lighting10%75,000——
Parking Brake10%45,000——
Service Brakes, Electric10%113,825——
Traction Control System10%46,000——

One complaint can list several problem areas, so shares can add up to more than 100%.

Complaints by year received

Peak: 2010, with 84 complaints
2003: 120032004: 142005: 820052006: 132007: 1020072008: 472009: 5720092010: 84842011: 5820112012: 312013: 2020132014: 302015: 2820152016: 172017: 1220172018: 82019: 720192020: 22021: 720212022: 32023: 320232024: 12025: 12025

n = 462 complaints · Source: NHTSA

2004 Volvo XC90 recalls (6)

Tap a recall to see the problem, the risk and the fix.

Equipment:electrical:navigational system(global positioning system)Nov 8, 2010 · NHTSA campaign 10V566000 · 416 vehicles

Problem: Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.

Risk: An overheated battery could lead to a fire.

Fix: Volvo advises owners to please stop using the garmin portable gps device immediately, and visit the garmin website to determine if their unit is affected. The unit's battery will be replaced with a new battery and a spacer will be inserted on top of the battery next to the pcb. This service will be performed free of charge. The safety recall began on november 18, 2010. Owners may contact garmin at 866-957-1981 or visit garmin's website at www.garmin.com/nuvibatterypcbrecall.

Fuel system, gasoline:delivery:fuel pumpDec 18, 2009 · NHTSA campaign 09V483000 · 158,733 vehicles

Problem: Volvo is recalling certain model year 2001-2005 s80, model year 2001-2004 v70, s60, xc70 and model year 2003-2005 xc90 vehicles sold in or registered in the states of alabama, arizona, arkansas, california, florida, georgia, hawaii, kentucky, louisiana, mississippi, nevada, new mexico, north carolina, oklahoma, south carolina, tennessee, texas, utah, virginia and the u.s. Territories. When exposed to certain environmental conditions (hot climate and temperature cycling) over time and in combination with varying fuel quality, the fuel pump can develop cracks in the fuel pump flange.

Risk: If the condition occurs vehicle owners may notice fuel smell and/or fuel leak which, in the presence of an ignition source, could result in a fire.

Fix: Dealers will inspect the fuel pump installed in the vehicle, and if necessary replace the fuel pump with a part of a modified design. This service will be performed free of charge. The safety recall began on january 15, 2010. Owners may contact volvo at 1-800-458-1552.

Steering:linkages:tie rod assemblyMay 5, 2006 · NHTSA campaign 06V155000 · 126,743 vehicles

Problem: On certain passenger vehicles,the outer tie rod ball joint can deform at high loads causing a loss of the clamping force and the nut may loosen, which may eventually lead to a fatigue fracture of the outer tie rod ball joint.

Risk: The driver may notice that the vehicle is difficult to maneuver increasing the risk of a crash.

Fix: Dealers will replace the outer ball joint tie rods with improved outer ball joint tie rods free of charge. The recall began on june 23, 2006. Owners may contact volvo at 1-800-458-1552.

Visibility:windshield wiper/washerApr 28, 2006 · NHTSA campaign 06V144000 · 122,431 vehicles

Problem: On certain vehicles, if the wiper arm is activated in extreme winter weather conditions and without lifting the wiper arms and cleaning the windshield prior to moving, the wiper arm might slip on its driveshaft, resulting in an inability to move the wipers from the park position.

Risk: Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility.

Fix: Dealers will replace the wiper arms and retaining nuts. The recall began on september 5, 2006. Owners may contact volvo cars at 1-800-458-1552.

WheelsNov 4, 2003 · NHTSA campaign 03V434000 · 2,586 vehicles

Problem: On certain sport utility vehicles, the front wheel speed sensors may be defective, causing an erroneous wheel speed signal.

Risk: This can adversely affect a number of vehicle functions, including brake, engine, transmission, and torque distribution control which rely on this signal for proper operation.

Fix: Dealers will replace the front wheel sensors. Owner notification began on december 8, 2003. Owners should contact volvo cars at 1-800-458-1552.

Seat belts:rear/otherOct 10, 2003 · NHTSA campaign 03V391000 · 18,692 vehicles

Problem: On certain sport utility vehicles, the seat belt attachment(s) for the second and third row seat(s) may not have been fitted properly.

Risk: In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of injury.

Fix: Dealers will inspect and repair the second and/or third row seat belt attachments. Owner notification began on december 8, 2003. Owners should contact volvo at 1-800-458-1552.

To see whether a specific car still has an open recall, enter its VIN on NHTSA's official recall lookup. You can also decode a VIN here.

NHTSA defect investigations

  • Central Electronic Module Failure (PE10025) — opened Jul 20, 2010, closed Nov 22, 2010.
  • Fuel pump leak (PE09039) — opened Aug 31, 2009, closed Dec 22, 2009, led to recall 09V483000.
  • Windshield wiper arm performance (PE05064) — opened Dec 2, 2005, closed May 10, 2006, led to recall 06V144000.

Recent owner reports

Short excerpts of the latest complaints filed with NHTSA, with personal details removed. Full reports can be searched on NHTSA.gov.

Instrument panel shuts down while driving on street. I believe it is the central electronic module that fails. It has happened numerous times and it is unsafe to drive without a speedometer, tachometer, odometer fuel gauge, and temperature gauge. It has now stopped altogether. Gauges just sit there…

Electrical System · received Mar 9, 2025 · NHTSA complaint 11647245

Unsure of what the issue is with the vehicle but smells like gas in my garage and I found a recall I was never notified about I moved from Washington to Las Vegas and never received any info regarding the fuel pump recall as well as a noise that’s been going on for a year now when I drive at 60…

Fuel/propulsion System · received Nov 22, 2024 · NHTSA complaint 11626848

Few days ago I came home, parked the car inside the garage and went inside. An hour later I went to the garage for something and noticed a very strong gasoline odor coming from the car. It is not coming from the reservoir and I did not put any fuel recently, so it can't be explained with a fuel…

Fuel/propulsion System · received May 16, 2023 · NHTSA complaint 11522371

The rear right door cannot be open from inside the car. It opens fine from outside. I am aware there is a child safety lock, but in this case the problem is somewhere else. Regardless of the child safety lock position, the door cannot be open. This is a hazard, because in case oof an accident the…

Structure · received May 16, 2023 · NHTSA complaint 11522373

Unknown..but water accumulated under the passenger seat under the amp and electrical components after a storm or rainy day.and its a lot of water when I brake i can hear a water fall..and water rushing and moving along the bottom. Of the car as I am steering im worried that the wiring and…

Electrical System · received Mar 17, 2023 · NHTSA complaint 11512307

Other Volvo XC90 years

← 2003 XC90 · 2005 XC90 →

See all Volvo XC90 problems by year, every Volvo model, or the Volvo VIN decoder.

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Frequently asked questions

What are the most common problems with the 2004 Volvo XC90?

Owners most often report electrical system, power train, fuel system, gasoline problems. The top one, electrical system, accounts for 158 complaints.

Was there a recall on the 2004 Volvo XC90?

Yes, 6 safety recalls. Enter your VIN at NHTSA.gov to check whether the repairs were done on your car.

Was the 2004 Volvo XC90 a good year?

Complaint data can't fully answer that, because counts aren't adjusted for sales. Compared with other XC90 model years, the 2004 has far more complaints than most years. Always get a pre-purchase inspection and check the VIN for open recalls.