no report yet
Electrical: navigational system(global positioning system)
Risk. AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
2004 Volvo XC90Problems, recalls & complaints
NHTSA has logged 462 owner complaints about the 2004 Volvo XC90, most often about the electrical system. It is covered by 6 safety recalls.
Source: NHTSA complaints, recalls, investigations and manufacturer recall reports, through March 9, 2025. Updated daily. Photo: Vauxford, CC BY-SA 4.0.
Complaints by system
Where the 2004 Volvo XC90 has problems
462 complaints grouped by the system owners reported.
158Electrical system6 crash/fire/injury
145Power train1 crash/fire/injury
40Fuel system, gasoline1 crash/fire/injury
34Fuel/propulsion system
32Exterior lighting
31Air bags
28Engine
24Engine and engine cooling
23Suspension
12922 other systems7 crash/fire/injury
| System | Complaints | Crash, fire or injury |
|---|---|---|
| Electrical system | 158 | 6 |
| Power train | 145 | 1 |
| Fuel system, gasoline | 40 | 1 |
| Fuel/propulsion system | 34 | 0 |
| Exterior lighting | 32 | 0 |
| Air bags | 31 | 3 |
| Engine | 28 | 0 |
| Engine and engine cooling | 24 | 0 |
| Suspension | 23 | 0 |
| 22 other systems | 129 | 7 |
Source: NHTSA Office of Defects Investigation. Complaints are submitted by the public and are not verified by NHTSA.
6 recalls
2004 Volvo XC90 recalls and how many were fixed
Each ring shows the share of affected cars repaired, from the manufacturer’s latest quarterly report to NHTSA. Recall repairs are free at authorized dealers.
no report yet
Delivery: fuel pump
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.
no report yet
Linkages: tie rod assembly
Risk. THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.
no report yet
Visibility: windshield wiper/washer
Risk. INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Show 2 more recalls
no report yet
Wheels
Risk. THIS CAN ADVERSELY AFFECT A NUMBER OF VEHICLE FUNCTIONS, INCLUDING BRAKE, ENGINE, TRANSMISSION, AND TORQUE DISTRIBUTION CONTROL WHICH RELY ON THIS SIGNAL FOR…
no report yet
Seat belts: rear/other
Risk. IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.
Recalls apply to specific cars. To see whether a recall is still open on yours, enter the 17-character VIN at nhtsa.gov/recalls or with Volvo.
Mileage at failure
When do electrical system problems start?
94kmiles, median
Based on the odometer reading in 146 electrical system complaints. 55% were reported before 100,000 miles.
10under 30k miles81under 100k miles65100k miles or more
Owner-reported costs
What owners say repairs cost
Dollar amounts owners wrote in their complaints when describing a repair or a quote. These are not price estimates; a system is shown only when at least 8 owners mentioned a cost.
Power train
25 owners mentioned a cost$5,335median
Middle half: $3,400 – $6,500
Electrical system
14 owners mentioned a cost$1,200median
Middle half: $1,050 – $1,370
If a problem is covered by a recall, the dealer fixes it for free. Some manufacturers also reimburse owners who paid for a repair before a recall was announced.
Best & worst years
2004 vs. every other XC90 year
Bars show complaints per model year. Colors show the CarFlaw verdict: complaints weighted for crashes, fires and injuries, adjusted for years on the road and compared with the XC90 median. How we score
'03'04'05'06'07'08'09'10'11'12'13'14'15'16'17'18'19'20'21'22'23'24'25
- Avoid
- Caution
- Solid
- Best
- Not rated
NHTSA crash tests
2004 Volvo XC90 safety ratings
2004 Volvo XC90 4-DR. w/SAB in NHTSA's New Car Assessment Program. Photos are from NHTSA's crash tests.
Frontal crashNot rated
Side barrierNot rated
- Rollover: 4 stars (17.9% risk)
- Stability control: Standard
- Forward collision warning: No
- Lane departure warning: No
3 investigations
NHTSA defect investigations
Federal investigations that included the 2004 Volvo XC90, and the recalls they led to.
- WINDSHIELD WIPER ARM PERFORMANCELed to recall 06V-144
- FUEL PUMP LEAKLed to recall 09V-483
- Central Electronic Module FailureNo recall
In owners' words
What XC90 owners report
Recent electrical system complaints filed with NHTSA, shortened. Personal details are removed.
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…
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…
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…
Own a 2004 XC90?
Decode your VIN to see the recalls for your exact car, then confirm open recalls with NHTSA.