CarModelProblems.com

2004 Volvo XC90 Problems & Recalls

Built from official NHTSA complaint and recall data · data through 07/14/2026

High complaint levelIts most-reported problem — Electrical System — runs 3.0× the fleet median for that category across the 2547 model-years tracked on this site.
462Complaints
6Recalls
9Crashes
3Fires
8Injured
0Deaths

Source: U.S. NHTSA complaint & recall data. Complaints are unverified reports from vehicle owners — a complaint is not a confirmed defect.

Is this problem acknowledged?

The most-reported problem — Electrical System (32.9% of complaints) — was examined in a now-closed NHTSA investigation that did not result in a recall.

Electrical System complaints here are 3.0× the median for that category across the 2547 model-years tracked on this site.

2 of the 6 most-reported categories on this page are backed by a recall or open investigation; the other 4 rest on owner reports alone.

Complaint categoryReportsOfficial statusReference
Electrical System152 · 32.9%Investigation closedPE10025
Power Train:automatic Transmission102 · 22.1%No official action
Power Train37 · 8%No official action
Fuel/propulsion System34 · 7.4%RecalledRecall 09V483000
Fuel System, Gasoline32 · 6.9%RecalledRecall 09V483000
Exterior Lighting30 · 6.5%No official action

Recalled = an NHTSA safety recall covers this category, so a free repair exists. Under investigation = NHTSA has an open probe but no recall yet. Investigation closed = NHTSA examined it and closed the probe — this is not a defect finding; where a closed probe led to a recall we name the campaign. Not available = recall or investigation data could not be confirmed for this vehicle — it is not a “no”. Categories are matched by NHTSA's top-level component. Check your VIN at nhtsa.gov/recalls.

Complaints by component

ELECTRICAL SYSTEM152 · 32.9%
POWER TRAIN37 · 8%
EXTERIOR LIGHTING30 · 6.5%
ENGINE28 · 6.1%
AIR BAGS26 · 5.6%
VEHICLE SPEED CONTROL16 · 3.5%
STEERING15 · 3.2%

Percentages are the share of the 462 complaints citing each component; one complaint can cite several components. “Unspecified / other” is NHTSA’s own catch-all category — we show it rather than hide it.

Recalls — 6 campaigns

Steering:linkages:tie Rod Assembly

NHTSA campaign 06V155000 · 2006 · reported 05/05/2006

THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Equipment:electrical:navigational System(global Positioning System)

NHTSA campaign 10V566000 · 2010 · reported 11/08/2010

AN OVERHEATED BATTERY COULD LEAD TO A FIRE. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Fuel System, Gasoline:delivery:fuel Pump

NHTSA campaign 09V483000 · 2009 · reported 12/18/2009

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. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Visibility:windshield Wiper/washer

NHTSA campaign 06V144000 · 2006 · reported 04/28/2006

INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Wheels

NHTSA campaign 03V434000 · 2003 · reported 11/04/2003

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. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Seat Belts:rear/other

NHTSA campaign 03V391000 · 2003 · reported 10/10/2003

IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Park it Park outside Specimen badges — shown on a recall card only when NHTSA sets the flag. None of the campaigns above carries either flag. Always check your own vehicle by VIN at nhtsa.gov/recalls.

What owners report

“I WAS WONDERING IF THERE HAS BEEN A RECALL FOR 2004 XC-90'S BECAUSE OF THERE EXTREMELY DANGEROUS ELECTRICAL FAILURE. THIS PAST WEEKEND AFTER ABOUT 3…”NHTSA complaint 10285471 — filed 09/28/2009 · ELECTRICAL SYSTEM
“2004 VOLVO XC90 2.5L TRANSMISSION. COMPLETE FAILURE AT 65,000 MILES REQUIRING REPLACEMENT OF ENTIRE TRANSMISSION. FOUR DAYS AFTER REPAIR, VEHICLE HAS LOUD ENGINE THUMP AND…”NHTSA complaint 10282656 — filed 09/02/2009 · ELECTRICAL SYSTEM
“WHEN WORKING ON THE AUDIO/CD/RADIO OF THE CAR, THIS GENERATES AN SRS SERVICE URGENT MESSAGE TO BE DISPLAYED ON THE DASH. THIS APPEARS TO BE…”NHTSA complaint 10270135 — filed 05/27/2009 · ELECTRICAL SYSTEM

Excerpts are shortened and scrubbed of personal details; they are individual, unverified reports.

Complaint trend by year filed

742011553620135042201532182017131120193172021332023312025

Frequently asked questions

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

Electrical system issues are the most-reported category, cited in 152 of 462 NHTSA complaints (32.9%), followed by power train:automatic transmission (102), power train (37), fuel/propulsion system (34). Complaints are unverified owner reports.

How many complaints does the 2004 Volvo XC90 have?

462 complaints were on file with NHTSA as of 07/14/2026. Of those, 9 involved a crash, 3 involved a fire, and 8 reported injuries. No deaths were reported.

Does the 2004 Volvo XC90 have any recalls?

Yes — 6 NHTSA safety recall campaigns, including campaign 06V155000. Recall repairs are free at authorized dealers. Check your specific vehicle by VIN at nhtsa.gov/recalls.

Has NHTSA acted on the 2004 Volvo XC90's reported problems?

2 of the 6 most-reported complaint categories on this page are backed by an NHTSA safety recall or open investigation; the rest are unverified owner reports. A recall means a free repair is available at authorized dealers.

Is a complaint proof of a defect?

No. Complaints are reports submitted by consumers to NHTSA. NHTSA does not verify individual complaints, and a complaint is not proof that a defect exists.

About this data — Complaint figures on this page are consumer reports submitted to the National Highway Traffic Safety Administration (NHTSA), a U.S. government agency. NHTSA does not verify individual complaints; a complaint is not proof that a defect exists, and counts reflect what owners chose to report, not confirmed failure rates. Recall information comes from official NHTSA safety recall campaigns; recall repairs are free at authorized dealers. Always check your specific vehicle by VIN at nhtsa.gov/recalls. CarModelProblems.com is an independent site and is not affiliated with NHTSA or any vehicle manufacturer. Data through 07/14/2026.