2004 Volvo XC90 recalls and problems

The 2004 Volvo XC90 has 6 recalls and 462 owner complaints on file with NHTSA; the most reported problem area is electrical system.

How the 2004 compares

Highest

Fewest complaintsMost complaints

Highest complaint count among 22 XC90 model years — the most of any year.

6recalls

462complaints

9crashes

3fires

8injuries

86,000median miles

Owner complaints filed with NHTSA, not verified and not adjusted for sales. Ranking compares this model's own years only.

Does your car have an open recall?
Recalls apply to specific vehicles. Only a VIN lookup on NHTSA's official site shows whether yours is affected and still unrepaired.

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6 recalls

Equipment

Nov 8, 2010 · NHTSA campaign 10V566000 · 416 vehicles

Problem: Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (GPS) units because the batteries on those units May overheat.

Original NHTSA wording

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

Risk: An overheated battery could lead to a fire.

Original NHTSA wording

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy & notes

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.

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 System

Dec 18, 2009 · NHTSA campaign 09V483000 · 158,733 vehicles

Problem: 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.

Original NHTSA wording

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.

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.

Original NHTSA wording

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.

Remedy & notes

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.

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> .

Steering

May 5, 2006 · NHTSA campaign 06V155000 · 126,743 vehicles

Problem: 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.

Original NHTSA wording

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.

Risk: The driver May notice that the vehicle is difficult to maneuver increasing the risk of a crash.

Original NHTSA wording

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

Remedy & notes

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 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.

Visibility

Apr 28, 2006 · NHTSA campaign 06V144000 · 122,431 vehicles

Problem: 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.

Original NHTSA wording

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.

Risk: Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility.

Original NHTSA wording

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

Remedy & notes

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.

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.

Wheels

Nov 4, 2003 · NHTSA campaign 03V434000 · 2,586 vehicles

Problem: On certain sport utility vehicles, the front wheel speed sensors May be defective, causing an erroneous wheel speed signal.

Original NHTSA wording

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

Risk: 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.

Original NHTSA wording

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 & notes

Dealers will replace the front wheel sensors. Owner notification began on December 8, 2003. Owners should contact Volvo cars at 1-800-458-1552.

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).

Seat Belts

Oct 10, 2003 · NHTSA campaign 03V391000 · 18,692 vehicles

Problem: On certain sport utility vehicles, the seat belt attachment(s) for the second and third row seat(s) May not have been fitted properly.

Original NHTSA wording

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

Risk: In the event of a crash, the seat occupant May not be properly restrained, increasing the risk of injury.

Original NHTSA wording

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

Remedy & notes

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 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).

Recall text as published by NHTSA and the manufacturer.

What owners complain about

Power Train145

Engine52

Vehicle Speed Control17

Owner complaints filed with NHTSA; one complaint can name several areas. Not verified by NHTSA.

Complaints by year filed

NHTSA investigations

Central Electronic Module Failure

PE10025 · opened Jul 20, 2010 · closed Nov 22, 2010

Summary

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 transmission operation.If the water reaches the CEM connector electrical faults may result.In response to such faults the CEM, a microprocessor controlled device, will attempt to reset by temporarily shutting down (for 100 milliseconds, or 0.1 seconds) and restarting; this effects various CEM functions including the instrument panel (IP) display, gauges, wipers and also the transmission gear (if it is in the overdrive range).During the reset owners may experience temporarily loss of the IP displays and an abnormal 'jerking' in the transmission/drivetrain.If the problem persist for 6 consecutive restart attempts, the CEM will enter a 'Limp Home' mode that disables non-essential electrical functions yet maintain safety critical functions such as low-beam headlights, low-speed wiper operation, brake lights, and non-overdrive transmission operation.Warning and error messages will also be illuminated in the IP display.Consumers reported experiencing conditions consistent with CEM resetting and the limp mode operation in their reports to both ODI and Volvo.No reports or allegations of crash or…

FUEL PUMP LEAK

PE09039 · opened Aug 31, 2009 · closed Dec 22, 2009 · led to recall 09V483000

Summary

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 INDICATE THE FREQUENCY OF COMPLAINTS/REPAIRS IS HIGHER IN THE HOT CLIMATE STATES. VOLVO WILL RECALL AND REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN/MATERIAL IN APPROXIMATELY 136,100 MY2001-2004 S60/V70/XC70, MY2001-2005 S80 AND MY2003-2005 XC90 VEHICLES IN 19 STATES.THESE STATES INCLUDE AL, AZ, AR, CA, FL, GA, HI, KY, LA, MS, NV, NM, NC, OK, SC, TN, TX, UT, VA AND THE US TERRITORIES.IN ADDITION, VOLVO WILL EXTEND THE WARRANTY COVERAGE TO 10 YEARS/150,000 MILES ON APPROXIMATELY 190,000 VEHICLES FOR THE REMAINING STATES.THIS RECALL/EXTENDED WARRANTY PROGRAM SUPERSEDES PREVIOUS 07V-152/TNN 23-198 PROGRAM ON MY2001-2002 VEHICLES.THIS INVESTIGATION IS CLOSED (SEE RECALL CAMPAIGN 09V-483).

WINDSHIELD WIPER ARM PERFORMANCE

PE05064 · opened Dec 2, 2005 · closed May 10, 2006 · led to recall 06V144000

Summary

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 EXISTING WINDSHIELD WIPER ARMS WITH A NEW REINFORCED DESIGN.BASED ON THIS ACTION, THE SUBJECT PE HAS BEEN CLOSED.

2004 vs. other Volvo XC90 years

Owner complaints by model year; the darker bar is the 2004. Click a bar to switch year.

Questions

Does the 2004 Volvo XC90 have recalls?

Yes — NHTSA lists 6 recall campaigns covering the 2004 Volvo XC90, the latest from Nov 8, 2010 (equipment). A recall applies to specific vehicles: enter your VIN at nhtsa.gov/recalls to see whether yours is affected and still open.

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

Owner complaints filed with NHTSA most often mention electrical system (158), power train (145), fuel system (77). Complaints are consumer reports and are not verified by NHTSA.