NHTSA vehicle safety data

2004 Volvo XC90 Recalls, Ratings & Complaints

The 2004 Volvo XC90 has 6 NHTSA recall campaigns and 462 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Volvo dealer.

NHTSA recall and complaint data for the 2004 Volvo XC90, plus NCAP crash-test ratings. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2004 Volvo XC90 owner complaints

Owners have filed 462 complaints with NHTSA about the 2004 Volvo XC90, describing incidents dated November 16, 2003 to March 6, 2025.

Most-cited components

Electrical System 158 complaints
Power Train 145 complaints
Fuel/Propulsion System 77 complaints
Engine 52 complaints
Exterior Lighting 32 complaints
Air Bags 31 complaints

Of the 462 complaints on file, 9 report a crash and 3 a fire; across all 462 complaints, owners report 8 injuries (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11647245 · Filed March 9, 2025
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…
ODI #11626848 · Filed November 22, 2024
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…
ODI #11522373 · Filed May 16, 2023
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…

Read all 462 complaints

Owner-reported

2004 Volvo XC90 mileage at failure

406 of the 462 complaints on file for the 2004 Volvo XC90 give the vehicle's mileage when the problem happened.

Mileage at failure by component, from owners' complaints to NHTSA
Component	Median	Middle half	Based on
Electrical System	Median 95,000 miles	Middle half 70,000–115,000 miles	Based on 144 complaints
Power Train	Median 80,000 miles	Middle half 60,000–105,000 miles	Based on 137 complaints
Fuel/Propulsion System	Median 100,000 miles	Middle half 70,000–140,000 miles	Based on 61 complaints
Engine	Median 90,000 miles	Middle half 75,000–115,000 miles	Based on 43 complaints

A component's median is its 50th percentile, and its middle half runs from its 25th to its 75th percentile.

Owners give the mileage themselves, often as a round number, and NHTSA doesn't check it. A complaint that names several components counts under each one, and mileages that can't be right, such as 999,999, or 50 miles on a five-year-old car, are left out.

These figures describe the complaints owners filed. They don't predict when a particular vehicle will have a problem, and vehicles that never had one aren't counted.

Mileage from NHTSA's complaints file of October 31, 2026. How these figures are worked out

NHTSA defect investigations

NHTSA's investigations file lists the 2004 Volvo XC90 in 3 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Preliminary Evaluation PE10-025: Central Electronic Module Failure
Closed November 22, 2010
Preliminary Evaluation PE09-039: FUEL PUMP LEAK
Closed December 22, 2009
- Recall 09V-483
Preliminary Evaluation PE05-064: WINDSHIELD WIPER ARM PERFORMANCE
Closed May 10, 2006
- Recall 06V-144

Open and recently closed NHTSA defect investigations

760 PORTABLE AUTOMOTIVE GPS UNITS/GARMIN

NHTSA #10V566000 · Equipment — Electrical — Navigational System(GLOBAL POSITIONING SYSTEM) · NHTSA notice

Reported November 8, 2010 · VOLVO CARS OF N.A. LLC.

Potentially affected: 416 vehicles

Volvo campaign R231 · Owners notified November 18, 2010

Defect description

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Safety consequence

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Manufacturer 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.

Notes

VOLVO SAFETY RECALL NO. R231.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

FUEL PUMP LEAK

NHTSA #09V483000 · Fuel System, Gasoline — Delivery — Fuel Pump · NHTSA notice

Reported December 18, 2009 · VOLVO CARS OF N.A. LLC.

Potentially affected: 158,733 vehicles

Volvo campaign R220 · Owners notified January 15, 2010 · Vehicles built August 7, 2002 – June 11, 2004 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety 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.

Manufacturer 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.

Notes

VOLVO SAFETY RECALL NO. R220.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

TIE ROD BALL JOINT FRACTURE

NHTSA #06V155000 · Steering — Linkages — Tie Rod Assembly · NHTSA notice

Reported May 5, 2006 · VOLVO CARS OF N.A. LLC.

Potentially affected: 126,743 vehicles

Volvo campaign R157 · Owners notified June 23, 2006 · Vehicles built March 3, 2003 – June 11, 2004 (per NHTSA)

Defect description

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.

Safety consequence

THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.

Manufacturer 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.

Notes

VOLVO RECALL NO. R157.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

WINDSHIELD WIPER ARM

NHTSA #06V144000 · Visibility — Windshield Wiper/Washer · NHTSA notice

Reported April 28, 2006 · VOLVO CARS OF N.A. LLC.

Potentially affected: 122,431 vehicles

Volvo campaign R156 · Owners notified September 5, 2006 · Vehicles built February 28, 2003 – June 11, 2004 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety consequence

INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.

Manufacturer 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.

Notes

VOLVO RECALL NO. R156.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATIONVOLVO RECALL NO. R156.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

VOLVO/FRONT WHEEL SPEED SENSOR

NHTSA #03V434000 · Wheels · NHTSA notice

Reported November 4, 2003 · VOLVO CARS OF N.A. LLC.

Potentially affected: 2,586 vehicles

Volvo campaign 127A · Owners notified December 8, 2003 · Vehicles built March 27, 2003 – April 16, 2003 (per NHTSA)

Defect description

ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.

Safety 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.

Manufacturer 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.

Notes

VOLVO RECALL NO. 127A.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

VOLVO/SEAT BELT ATTACHMENTS

NHTSA #03V391000 · Seat Belts — Rear/Other · NHTSA notice

Reported October 10, 2003 · VOLVO CARS OF N.A. LLC.

Potentially affected: 18,692 vehicles

Volvo campaign 127 · Owners notified December 8, 2003 · Vehicles built April 22, 2002 – April 24, 2003 (per NHTSA)

Defect description

ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.

Safety consequence

IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.

Manufacturer 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.

Notes

VOLVO RECALL NO. 127.CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).

2004 Volvo XC90 4-DR. w/SAB

—

out of 5

Overall Safety Rating

Not Rated

Frontal Crash

Not Rated

Driver: 5, Passenger: 4

Side Crash

Not Rated

Driver: 5, Passenger: 5

Side Pole

Not Rated

Rollover

18% rollover risk

Safety Technology

Electronic Stability Control

3 investigations

462 owner complaints have been filed with NHTSA for the 2004 Volvo XC90.

Electrical System

ODI #11647245

Incident: March 6, 2025 · Filed: March 9, 2025

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

Electrical System; Engine; Fuel/Propulsion System

ODI #11626848

Incident: November 8, 2024 · Filed: November 22, 2024

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

Structure

ODI #11522373

Incident: April 7, 2023 · Filed: May 16, 2023

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.

Fuel/Propulsion System

ODI #11522371

Incident: May 9, 2023 · Filed: May 16, 2023

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.

Electrical System

ODI #11512307

Incident: March 10, 2023 · Filed: March 17, 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 ??

Fuel System, Gasoline

ODI #11492882

Incident: November 9, 2012 · Filed: November 9, 2022

The contact owns a 2004 Volvo XC90. The contact stated that after refueling the vehicle, his wife noticed an abnormally strong gasoline odor. The contact's wife was able to continue driving the vehicle; however, the failure would return after refueling or on rainy days. The contact related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline) however, the VIN was not included. The dealer and the manufacturer were notified of the failure and informed the contact that they could not assist as the VIN was not under recall. The vehicle was not diagnosed or repaired. The failure mileage was approximately 30,000.

Fuel System, Gasoline

ODI #11487737

Incident: September 17, 2022 · Filed: October 3, 2022

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.

Electrical System

ODI #11466954

Incident: May 26, 2022 · Filed: June 1, 2022

On May 26, 2022, I was stuck in traffic for four hours, and the car's CEM (central electronic module) overheated causing the dashboard to shut down three times, meaning I lost all instrument readings. After each time the dashboard shut down, I had to pull over and reset fuse #27 to have the dashboard come back online temporarily. Because the CEM was already overheated due to its design flaw with improper ventilation, the dashboard would shut down again and again. A Google search would show this is a very common issue for 2004 Volvo models and before. Driving without any instrument readings is totally unsafe. I strongly urge you to force Volvo to issue a recall for 2004 and before models and fix the CEM overheating problem.

Electrical System; Exterior Lighting; Engine

ODI #11440237

Incident: October 16, 2021 · Filed: November 12, 2021

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.

Unknown or Other; Engine; Forward Collision Avoidance

ODI #11421934

Incident: November 20, 2020 · Filed: June 22, 2021

is been stolen form my home and trying to fine it

Other Volvo XC90 model years

Check your 2004 Volvo XC90 VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Volvo XC90 at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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