2004 Volvo XC90: problems, recalls and reliability
6 recalls and 462 owner complaints on record; the weakest area is power train (27% of complaints); the 2003 and 2005 and 2006 model years look more trouble-free.
Data updated weekly · latest recall Nov 2010
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 462 owner complaints filed with NHTSA for this exact model year.
“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 and bounce”Owner report · Electrical System · Mar 2025
“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 miles an hour I've had it looked at and no one seems to know what that issue is”Owner report · Fuel/Propulsion System · Nov 2024
“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 spill. I suspect it is coming from the fuel pump. I as hoping or it to goo away, but it did not. It has been a week already.”Owner report · Fuel/Propulsion System · May 2023
Show 7 more owner reports
“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 passenger will e trapped inside the car.”Owner report · Structure · Apr 2023
“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 will be damaged by water exposure the battery always dies wires soaked and sitting in water underneath passenger and never can completely get the moisture smell out of front seat area..mildew..why is this water leaking or not draining correctly ??”Owner report · Electrical System · Mar 2023
“The contact owns a 2004 Volvo XC90. The contact stated that after his wife started the vehicle, she smelled the odor of gasoline. The contact had been advised by his wife that the vehicle was taking longer to start up and sometimes required two or three attempts to start the vehicle. The contact stated no warning light was illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic to be diagnosed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline). The failure mileage was approximately 212,000.”Owner report · Fuel System, Gasoline · Sep 2022
“While driving on the highway "SRS urgent" text came on, also hear clicking sounds under dash on driver side, then dashboard indicator lights completely disappear (speed, fuel, temperature, etc) . Extremely hot under driver side dash. Fortunately, still able to steer and brake. This has happened twice now. Mechanic believes most likely CEM failure or DIM failure. My vehicle also has a wet A-pillar fabric (Volvo forums indicate possible cause of failure). I removed drivers A-pillar and found a clogged drain tube from the sunroof. However, did not notice any obvious signs of water inside the vehicle, though it hasnt rained for over a month when this happened.”Owner report · Electrical System · Oct 2021
“Inside smells of gasoline after starting, and while driving. Persistent. Nauseating while driving. Windows must be let down while driving.”Owner report · Fuel/Propulsion System · Apr 2021
“The fuel pump under the back seat is cracked and leaking fuel. This is referenced in NHTSA recall number 09v483000. O'steen volvo in jacksonville refuses to acknowledge there was ever a problem with this. It is all over the internet.the vehicle is not driveable as is. The car is soaked with gasoline. Apparently the fuel pump housing dries out from heat and cracks. We need some help here. It would be better if someone in saint augustine florida could do this recall work for us as we really don't want to deal with o'steen after they have blown us off.”Owner report · Fuel/Propulsion System · Jan 2021
“Transmision is struggling on 3rd or 4th shift, I read on internet many colvos this trim failing and been rebuilted and still failing”Owner report · Engine · Oct 2019
When filing, owners marked a crash in 9 of these complaints and injuries in 8 - self-reported to NHTSA, not verified accident statistics.
Recalls - 6 campaigns
ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.
Remedy: 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.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Remedy: 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.
ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.
Remedy: DEALERS WILL REPLACE THE FRONT WHEEL SENSORS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
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.
Remedy: 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.
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.
Remedy: 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.
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.
Remedy: 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.
Specifications
Factory options offered for the 2004 model year, decoded from the NHTSA vPIC database. Individual vehicles have one of each.
How other years compare
Check your exact XC90 by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2004 Volvo XC90 reliable?
NHTSA has 462 owner complaints and 6 recall campaigns on record for the 2004 Volvo XC90. The most complained-about area is power train (27% of complaints).
At what mileage do 2004 Volvo XC90 problems usually appear?
Half of the complaints that mention mileage were filed at 86,802 miles or less.
Does the 2004 Volvo XC90 have open recalls?
6 recall campaigns have been issued, the latest concerning seat belts:rear/other. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.