NHTSA lists 462 complaints for the 2004 Volvo XC90, 9 of them mention a crash and 3 mention a fire. 7 complaints mention an injury, with 8 injuries and 0 deaths reported.
Data build 2026-10-09.
NHTSA lists this vehicle as VOLVO XC90.
Model-generated complaint tags: This model year has not been tagged.
Recalls
See new recalls and investigations this week.
6 recalls.
Date: 2010-11-08. Systems: EQUIPMENT.
Defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT. (excerpt)
Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE. (excerpt)
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 GARMI (excerpt)
Do not drive: No. Park outside: No.
Date: 2009-12-18. Systems: FUEL SYSTEM, GASOLINE.
Defect: 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 EXPOSE (excerpt)
Consequence: 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. (excerpt)
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. (excerpt)
Do not drive: No. Park outside: No.
Date: 2006-05-05. Systems: STEERING.
Defect: 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.
Consequence: THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.
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.
Do not drive: No. Park outside: No.
Date: 2006-04-28. Systems: VISIBILITY.
Defect: 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.
Consequence: INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
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.
Do not drive: No. Park outside: No.
Date: 2003-11-04. Systems: WHEELS.
Defect: ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.
Consequence: 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.
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.
Do not drive: No. Park outside: No.
Date: 2003-10-10. Systems: SEAT BELTS.
Defect: ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.
Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.
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.
Do not drive: No. Park outside: No.
Investigations
3 investigations; 0 open.
PE10025
Opened: 2010-07-20. Closed: 2010-11-22.
Central Electronic Module Failure
Volvo acknowledged a problem affecting some subject vehicles involving water seepage into the plenum box area in the engine compartment.When this occurs water may enter into the interior / passenger compartment and track along the wiring harness for the Central Electronic Module (CEM), the device that controls many of the vehicle's electrical functions including wiper operation, lighting, and tran
Systems: ELECTRICAL SYSTEM.
Linked campaign numbers: None listed.
PE09039
Opened: 2009-08-31. Closed: 2009-12-22.
FUEL PUMP LEAK
VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER MY2001-2005 S60/S80/V70/XC70 AND MY2003/2005 XC90 VEHICLES.REVIEW OF THE VOLVO DATA IN
Systems: FUEL SYSTEM, GASOLINE.
Linked campaign numbers: 09V483000.
PE05064
Opened: 2005-12-02. Closed: 2006-05-10.
WINDSHIELD WIPER ARM PERFORMANCE
THE MANUFACTURER NOTIFIED NHTSA BY LETTER DATED APRIL 21, 2006, THAT A SAFETY RECALL HAS BEEN INITIATED FOR CORRECTION OF THIS PROBLEM ON CERTAIN MODEL YEAR 2003 - 2006 VOLVO XC90 VEHICLES. THE RECALL AFFECTS APPROXIMATELY 122,400 SUBJECT VEHICLES PRODUCED BETWEEN AUGUST 2002 AND OCTOBER 2005.NHTSA HAS ASSIGNED NO. 06V-144 TO THIS RECALL ACTION.THE CORRECTIVE ACTION WILL CONSIST OF REPLACING THE E
Systems: VISIBILITY.
Linked campaign numbers: 06V144000.
Manufacturer communications
222 manufacturer communications.
Communications by system| System | Count |
|---|
| EQUIPMENT | 112 |
|---|
| ELECTRICAL SYSTEM | 64 |
|---|
| EQUIPMENT ADAPTIVE/MOBILITY | 18 |
|---|
| ENGINE AND ENGINE COOLING | 14 |
|---|
| UNKNOWN OR OTHER | 13 |
|---|
| WHEELS | 11 |
|---|
| POWER TRAIN | 9 |
|---|
| SEAT BELTS | 9 |
|---|
11032678
Date: 2026-04-23. Type: Service Bulletin/Repair Instructions. Systems: ENGINE.
This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not required.
11032671
Date: 2026-04-07. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval. Current items under prior approval are listed in the "Service" sec
11027173
Date: 2025-12-06. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
This is a Technical Journal. Vehicle type and platform identification.
11020437
Date: 2025-04-10. Type: Service Bulletin/Repair Instructions. Systems: EXTERIOR LIGHTING.
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: a ?Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. a ?Connect to the vehicle over a wired connection using a
11016002
Date: 2025-02-21. Type: Service Campaign. Systems: UNKNOWN OR OTHER.
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing issue with the key fob. As a result, there is a possibil
11015994
Date: 2025-02-13. Type: Service Campaign. Systems: UNKNOWN OR OTHER.
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that there is a pairing issue with the key fob. As a result, there is a possibil
11014112
Date: 2025-01-16. Type: Service Bulletin/Repair Instructions. Systems: EXTERIOR LIGHTING.
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: a ?Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V. a ?Connect to the vehicle over a wired connection using a
11014113
Date: 2025-01-16. Type: Service Bulletin/Repair Instructions. Systems: UNKNOWN OR OTHER.
This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory
11007925
Date: 2024-08-14. Type: Other. Systems: ELECTRICAL SYSTEM.
Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service
10249191
Date: 2024-01-12. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM.
This is a Technical Journal: 12V Battery Testing Method