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2004 Volvo XC90

Owner reports · Recalls · Investigations

More warning signs than most XC90 years

Owner complaints for the 2004 Volvo XC90 are substantially higher than the model-year median of 34.

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When problems were reported

Mileage at the reported incident

410 reports with mileage · 52 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 158 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 145 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 40 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports3 fire reports7 injury reports

Electrical System complaints

158 reports
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92,565 miles · Aug 2, 2010
Electrical System

I HAVE BEEN HAVING AN ISSUE WITH MY 2004 VOLVO XC90 WHICH THE DEALERSHIP HAS NOT BEEN ABLE TO CORRECT FOR MY FOURTH VISIT NOW. THE ENTIRE ELECTRICAL SYSTEM SHUTS DOWN WHILE DRIVING ON THE HIGHWAY. THIS HAS BEEN HAPPENING AND EACH TIME I TAKE IT IN, THEY ARE UNABLE TO REPLICATE THE ISSUE AND OF COURSE FIND SOMETHING ELSE TO REP…

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I HAVE BEEN HAVING AN ISSUE WITH MY 2004 VOLVO XC90 WHICH THE DEALERSHIP HAS NOT BEEN ABLE TO CORRECT FOR MY FOURTH VISIT NOW. THE ENTIRE ELECTRICAL SYSTEM SHUTS DOWN WHILE DRIVING ON THE HIGHWAY. THIS HAS BEEN HAPPENING AND EACH TIME I TAKE IT IN, THEY ARE UNABLE TO REPLICATE THE ISSUE AND OF COURSE FIND SOMETHING ELSE TO REPAIR. I HAVE BEEN LUCKY AS NOT HAVE BEEN IN HEAVY TRAFFIC WHEN IT HAPPENS, BUT I COULD IMAGINE IT COULD CAUSE A HORRIBLE ACCIDENT. THE LAST TIME THIS HAPPENED WAS ABOUT 7/18. I WAS DRIVING ABOUT 70MPH ON THE FREEWAY AND THE CAR MADE A 'THUMP' AND ALL THE LIGHTS AND GAUGES TURNED OFF MOMENTARILY AND STARTED BACK UP AGAIN. I SLOWED DOWN TO ABOUT 60MPH AND MOVED TO THE RIGHT SIDE AND THE EXACT SAME THING HAPPENED AGAIN ABOUT 5 MIN LATER. LUCKILY I WAS CLOSE TO THE EXIT WHERE MY MECHANIC SHOP WAS SO I SLOWED DOWN TO EXIT. ALL OF THE LIGHTS ON THE INSTRUMENT PANEL TURNED OFF, AS WELL AS THE AIRCONDITIONING (115 DAY IN PHX) AND A WARNING LIGHT FLASHED SAYING I HAD A BREAK FAILURE. I WAS ABLE TO LIMP TO THE MECHANICS AND LEFT THE CAR RUNNING SO THEY COULD SEE THE ENGINE WAS ON, BUT NOTHING ELSE. THEY DID NOT HAVE THE EQUIPMENT TO CHECK THE 'CODE' ON A VOLVO. THEY WERE ABLE TO RE-SET IT BY DISCONNECTING THE BATTERY, AND THE LIGHTS WORKED AGAIN. AS I PULLED OUT OF THE MECHANICS, THE CAR THUMPED AGAIN AND I ONCE AGAIN LOST ALL POWER. I LIMPED THE CAR HOME WITH PLANS TO DRIVE IT EARLY IN THE MORNING BEFORE IT GOT TOO HOT, TO THE VOLVO DEALERSHIP. IN THE MORNING, THE CAR WOULD NOT START AT ALL. I CALLED A TOW TRUCK AND HAD IT BROUGHT OVER. THE VOLVO DEALERSHIP ONCE AGAIN COULD FIND NOTHING WRONG, BUT FOUND SOMETHING TO FIX AND CHARGE ME FOR, THE IMPULSE SENSOR ($250). I FINALLY GOT THE CAR BACK ON JULY 29TH, 10 DAYS LATER. THIS ISSUE HAS BEEN EXPERIENCED BY MANY 04/05 XC90 OWNERS AS DESCRIBED IN THIS FORUM,HTTP://WWW.VOLVO-FORUMS.COM/T23397-XC90-ELECTRICALENGINE-POWER-FAILURE.HTM. I ASK THAT YOU HAVE VOLVO FIX THIS ISSUE, BEFORE SOMEONE DIES. *TR

NHTSA ODI #10346921

55,000 miles · Jul 30, 2010
Electrical System

OUR 2004 VOLVO XC90 ALWAYS HAD AN ERRATIC ELECTRICAL SYSTEM. LAST YEAR IT SUDDENLY GOT WORSE WHEN THE ENTIRE ELECTRICAL SYSTEM, INCLUDING BRAKE LIGHTS, TURN SIGNALS AND GAUGES STARTED TO FAIL AND WITHIN A FEW DAYS WERE COMPLETELY NON-FUNCTIONING. THE LOCAL VOLVO DEALER CHARGED US ABOUT $1200 FOR A NEW COMPUTER-RELATED PART. *TR

NHTSA ODI #10346436

67,100 miles · Jul 30, 2010
Electrical System

RADIO TURNS ON AND OFF SPONTANEOUSLY ESPECIALLY WHEN HEATED SEATS ARE TUNED ON. *TR

NHTSA ODI #10346398

104,365 miles · Jul 28, 2010
Electrical SystemExterior Lighting

ON OUR 2004 VOLVO XC90 THE HEADLIGHTS SUDDENLY WENT DARK, NO LOW OR HIGH BEAMS AT ALL. I AM NOW BEING TOLD IT IS A MODULE AND THE REPAIR COST IS IN EXCESS OF $1200. THE CAR HAS HID HEADLIGHTS. THIS OUTAGE CREATED A VERY SERIOUS SAFETY ISSUE IN THAT WE WERE DRIVING UP HIGHWAY 395 AT NIGHT WHEN THE COMPLETE FAILURE OF THE HEADLI…

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ON OUR 2004 VOLVO XC90 THE HEADLIGHTS SUDDENLY WENT DARK, NO LOW OR HIGH BEAMS AT ALL. I AM NOW BEING TOLD IT IS A MODULE AND THE REPAIR COST IS IN EXCESS OF $1200. THE CAR HAS HID HEADLIGHTS. THIS OUTAGE CREATED A VERY SERIOUS SAFETY ISSUE IN THAT WE WERE DRIVING UP HIGHWAY 395 AT NIGHT WHEN THE COMPLETE FAILURE OF THE HEADLIGHTS OCCURRED. IN RESEARCHING THE ISSUE ON THE INTERNET IT APPEARS IT IS A RELATIVELY COMMON FAILURE. *TR

NHTSA ODI #10345921

75,000 miles · Jul 26, 2010
Air BagsElectrical SystemInterior Lighting

AFTER DRIVING 125 MILES WITHOUT INCIDENT, WE LEFT OUR 2004 VOLVO XC 90 T6 AWD PARKED FOR 4 HOURS BEFORE DRIVING AGAIN. AFTER LESS THAN A HALF MILE AT LOW SPEED, THERE WAS A "THUMP" FROM THE FRONT OF THE CAR, THE WIPERS CYCLED, THE GAUGES ALL WENT BLANK, SOME OF THE WINDOWS STOPPED WORKING, THE A/C WENT OUT (BLOWER STAYED ON). …

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AFTER DRIVING 125 MILES WITHOUT INCIDENT, WE LEFT OUR 2004 VOLVO XC 90 T6 AWD PARKED FOR 4 HOURS BEFORE DRIVING AGAIN. AFTER LESS THAN A HALF MILE AT LOW SPEED, THERE WAS A "THUMP" FROM THE FRONT OF THE CAR, THE WIPERS CYCLED, THE GAUGES ALL WENT BLANK, SOME OF THE WINDOWS STOPPED WORKING, THE A/C WENT OUT (BLOWER STAYED ON). THE CAR STAYED ON, BUT SEEMED "STUCK" IN SECOND GEAR AND THE BRAKES BECAME "SPONGY," BUT OPERABLE. TURN SIGNALS WERE INOPERABLE AND THE POWER STEERING WENT OUT. THE INDICATOR LIGHT ON THE GEAR SHIFT WENT OUT AND THE CENTRAL LOCKING SYSTEM STOPPED FUNCTIONING. WE GOT OUT OF TRAFFIC AND INTO THE SHADE. I CHECKED ALL FUSES AND TRIED TO RESTART THE CAR. IT WOULD RESTART, BUT WITHIN SECONDS THERE WERE MULTIPLE "CLICKS" COMING FROM THE AREA NEAR THE FUSE BOX IN THE PASSENGER COMPARTMENT FOLLOWED BY THE ELECTRICAL FAILURES DESCRIBED ABOVE. AFTER LETTING THE CAR SIT FOR A COUPLE OF HOURS WE MOVED IT TO A SECURE LOCATION TWO MILES AWAY. DURING THAT DRIVE ALL OF THE ABOVE PROBLEMS HAPPENED AGAIN, INCLUDING THE ENGINE BEING "STUCK" IN SECOND GEAR. AFTER LETTING THE CAR SIT OVERNIGHT, IT STARTED AND RAN WITHOUT INCIDENT. HOWEVER, THE "CHECK ENGINE" LIGHT AND THE "SRS" LIGHT HAVE REMAINED ON. A REPAIR SHOP COULD NOT DIAGNOSE THE PROBLEM. PRIOR TO THIS INCIDENT, THE SAME THINGS HAPPENED TO MY WIFE IN THE SAME CAR. THE SYMPTOMS LASTED A FEW SECONDS AND DISAPPEARED. *TR

NHTSA ODI #10345228

83,000 miles · Jul 22, 2010
Electrical System

2004 VOLVO XC90 2.5T AWD. INTERMITTENT "THUMPING" AT HIGH SPEEDS CAUSING THE CAR TO JOLT/LURCH SLIGHTLY. THIS HAS HAPPENED ON AND OFF FOR 2 MONTHS NORMALLY AT HIGHWAY SPEEDS. YESTERDAY I WAS ON A 4 HOUR HIGHWAY DRIVE HOME FROM VACATION AND THE THUMPING/JOLTING HAPPENED ABOUT 5 TIMES. ULTIMATELY MY CAR LOST COMPLETE ELECTRICA…

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2004 VOLVO XC90 2.5T AWD. INTERMITTENT "THUMPING" AT HIGH SPEEDS CAUSING THE CAR TO JOLT/LURCH SLIGHTLY. THIS HAS HAPPENED ON AND OFF FOR 2 MONTHS NORMALLY AT HIGHWAY SPEEDS. YESTERDAY I WAS ON A 4 HOUR HIGHWAY DRIVE HOME FROM VACATION AND THE THUMPING/JOLTING HAPPENED ABOUT 5 TIMES. ULTIMATELY MY CAR LOST COMPLETE ELECTRICAL POWER AT HIGHWAY SPEED AND FORTUNATELY I WAS ABLE TO COAST OFF THE HIGHWAY UNSCATHED BUT OTHERS MAY NOT BE AS FORTUNATE. INCREDIBLY DANGEROUS ISSUE. *TR

NHTSA ODI #10344643

45,000 miles · Jul 2, 2010
Electrical System

I OWN A 2004 VOLVO XC-90. I HAVE OWNED THE CAR SINCE APRIL 2004. APPROXIMATELY SEVEN MONTHS AGO, I STARTED EXPERIENCING INTERMITTENT ELECTRICAL PROBLEMS (RADIO AND NAVIGATION DISPLAY DISAPPEARING, ENGINE SERVICE ALERTS, ETC). SINCE THE INITIAL PROBLEMS WITH THE RADIO, THE PROBLEMS HAVE PROGRESSED TO THE POINT OF COMPLETE ELECTRI…

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I OWN A 2004 VOLVO XC-90. I HAVE OWNED THE CAR SINCE APRIL 2004. APPROXIMATELY SEVEN MONTHS AGO, I STARTED EXPERIENCING INTERMITTENT ELECTRICAL PROBLEMS (RADIO AND NAVIGATION DISPLAY DISAPPEARING, ENGINE SERVICE ALERTS, ETC). SINCE THE INITIAL PROBLEMS WITH THE RADIO, THE PROBLEMS HAVE PROGRESSED TO THE POINT OF COMPLETE ELECTRICAL FAILURES WHILE DRIVING ON THE HIGHWAY AT SPEEDS OF OVER 55MPH. THESE INCIDENTS INVOLVED A COMPLETE SHUT DOWN OF THE GAUGES (TACHOMETER, SPEEDOMETER, FUEL GAUGE, AS WELL AS AUDIO SYSTEM). I HAVE LEARNED FROM ONLINE SEARCHES (SPECIFICALLY, WWW.ABOUTAUTOMOBILE.COM/COMPLAINT/2004/VOLVO/XC90/ELECTRICAL+SYSTEM) THAT THESE INCIDENTS ARE BEING EXPERIENCED BY MANY OTHER VOLVO XC-90 OWNERS. SUCH INCIDENTS HAVE CAUSED MANY OWNERS TO TAKE THE CAR TO THEIR VOLVO SERVICE DEPARTMENT ONLY TO BE TOLD, AS I WAS THAT DETERMINING THE PROBLEM WOULD BE COSTLY AND THAT THERE HAVE BEEN NOT OTHER COMPLAINTS OR RECALLS BY VOLVO. THE PROBLEMS I AM EXPERIENCING ARE NOW ONGOING WHETHER I AM IN TOWN OR ON THE HIGHWAY. IT WAS WITH AN INITIAL EXPENDITURE OF NEARLY $400 AND AN EXPECTED UPCOMING EXPENDITURE OF $1200. THE LATTER AMOUNT IS THE PRICE FOR LABOR AND PARTS TO REPLACE THE CEM BOARD. I TOLD MY MECHANIC OF THE FINDINGS FROM MY ONLINE SEARCH AND HAD TO REQUEST THE REPLACEMENT OF THIS PART. THE PROBLEMS I AM EXPERIENCING ARE NOT ONLY DANGEROUS AT HIGH SPEEDS BUT I HAVE FOUND THAT I AM NOW HAVING PROBLEMS WITH THE LATCH THAT UNLOCKS THE HATCHBACK TRUNK AND ACCESS TO THE GAS TANK. MY CAR HAS LESS THAN 50,000 MILES AND REQUIRED SERVICE HAS BEEN DONE AT THE SAME DEALERSHIP SINCE MY PURCHASE OF THE VEHICLE. I HAVE TALKED WITH VOLVO CUSTOMER SERVICE AND THEY HAVE NOT YET ISSUED A RECALL. I HAVE NOT FOUND ANY RECORDS OF DEATHS OR INJURIES BEING CAUSED BY THE ELECTRICAL FAILURES, BUT IF THE SITUATIONS ENCOUNTERED BY OTHER OWNERS ARE LIKE MINE IT IS ONLY A MATTER OF TIME. THE VEHICLE LITERALLY CAN CAUSE A SLOWDOWN AND IMPAIR THE ABILITY OF THE DRIVER TO AVOID ACCIDENTS. *TR

NHTSA ODI #10341256

40,000 miles · Jun 11, 2010
Electrical System

I HAVE A 2004 XC90. I HAVE BEEN HAVING ELECTRICAL FAILURE PROBLEMS WITH MY CAR WHERE THE CAR JUST STALLS WHILE DRIVING AT SPEEDS OF 50MPH RANDOMLY FOR THE PAST THREE YEARS AND HAVE BROUGHT THE CAR INTO THE CALABASAS DEALER NUMEROUS TIMES AND ALSO TO AN INDEPENDENT AUTO MECHANIC AND NO ONE IS ABLE TO DUPLICATE THE STALL OF THE E…

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I HAVE A 2004 XC90. I HAVE BEEN HAVING ELECTRICAL FAILURE PROBLEMS WITH MY CAR WHERE THE CAR JUST STALLS WHILE DRIVING AT SPEEDS OF 50MPH RANDOMLY FOR THE PAST THREE YEARS AND HAVE BROUGHT THE CAR INTO THE CALABASAS DEALER NUMEROUS TIMES AND ALSO TO AN INDEPENDENT AUTO MECHANIC AND NO ONE IS ABLE TO DUPLICATE THE STALL OF THE ELECTRICAL SYSTEM AND THEREFORE NOONE IS ABLE TO DIAGNOSE THE SOLUTION TO THE HAZARD THAT OCCURS WHEN THE CAR STALLS AND THEREFORE NO ONE IS ABLE TO FIX THE PROBLEM. THE DEALER ASSURES ME THAT IT IS NOT A SAFETY ISSUE, JUST A NUISANCE. I RESEARCHED AND FOUND THAT THERE ARE 100S OF COMPLAINTS OF SIMILAR ISSUES FOR THIS CAR. TODAY THIS SAME ISSUE HAPPENED AT MUCH LOWER SPEEDS TWO TIMES WITHIN FIVE MINUTES. I REQUEST THAT THIS ISSUE BE RESEARCHED AND THE MANUFACTURER FIX THE PROBLEM. *TR

NHTSA ODI #10335756

45,000 miles · Jun 10, 2010
Electrical System

IN MARCH 2010, 04 XC90 LOST POWER WHILE DRIVING ON HIGHWAY AT ABOUT 65MPH. DASHBOARD LIGHTS, RADIO ALL CUT OFF, CAR LUNGED FORWARD, AND IN 1-2 SECONDS DASHBOARD LIGHTS AND RADIO POWER ON AGAIN. TOOK TO VOLVO DEALERSHIP, THEY COULDN'T DUPLICATE THE ISSUE BUT DIAGNOSTICS SAID THEY NEEDED TO REPLACE THE STEERING COLUMN MODULE WHIC…

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IN MARCH 2010, 04 XC90 LOST POWER WHILE DRIVING ON HIGHWAY AT ABOUT 65MPH. DASHBOARD LIGHTS, RADIO ALL CUT OFF, CAR LUNGED FORWARD, AND IN 1-2 SECONDS DASHBOARD LIGHTS AND RADIO POWER ON AGAIN. TOOK TO VOLVO DEALERSHIP, THEY COULDN'T DUPLICATE THE ISSUE BUT DIAGNOSTICS SAID THEY NEEDED TO REPLACE THE STEERING COLUMN MODULE WHICH SHOULD FIX PROBLEM. THIS DIDN'T FIX THE PROBLEM BECAUSE CAR DID THE SAME THING (LOSE POWER, LUNGE FORWARD) AROUND SAME SPEED 2 MONTHS LATER. DEALER COULD NOT DUPLICATE, RETURNED CAR TO ME. A WEEK LATER, JUNE 3, CAR WON'T START AT ALL, TOWED TO VOLVO DEALERSHIP. THIS TIME THEY SAY THE CEM (CENTRAL ELECTRONIC MODULE) NEEDS TO BE REPLACED AND THAT SHOULD SOLVE IT. THEY REPLACED CEM, SO FAR CAR RUNS FINE. THERE HAVE BEEN TOO MANY COMPLAINTS ABOUT THIS AND VOLVO IS NOT TAKE OWNERSHIP OF THIS PROBLEM. *TR

NHTSA ODI #10335606

89,000 miles · Apr 29, 2010
Electrical System

TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT SPEEDS OF 65 MPH, THERE WAS AN UNUSUALLY LOUD NOISE FOLLOWED BY AN IMMEDIATE LOSS OF ALL PANEL LIGHTS. THE CONTACT WAS ABLE TO MOVE THE VEHICLE FROM THE ROADWAY AND SHUT OFF THE ENGINE. UPON RESTARTING, THE SRS AIR BAG AND CHECK ENGINE WARNING LIGHTS REMAINED ILLUMINATED. …

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT SPEEDS OF 65 MPH, THERE WAS AN UNUSUALLY LOUD NOISE FOLLOWED BY AN IMMEDIATE LOSS OF ALL PANEL LIGHTS. THE CONTACT WAS ABLE TO MOVE THE VEHICLE FROM THE ROADWAY AND SHUT OFF THE ENGINE. UPON RESTARTING, THE SRS AIR BAG AND CHECK ENGINE WARNING LIGHTS REMAINED ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER TWICE BUT THE FAILURE WAS UNABLE TO BE DUPLICATED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 89,000 AND THE CURRENT MILEAGE WAS 99,000. UPDATED 6/21/10 *CN THE CONSUMER STATED AFTER DRIVING FOR ABOUT THREE HOURS, THE RADIO TURN SIGNALS STOPPED WORKING. UPDATED 06/24/10.*JB

NHTSA ODI #10328127

Official recalls

6

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

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

Consequence & remedy

Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

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.

09V483000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2009

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.

Consequence & remedy

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.

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.

06V155000 · Steering:linkages:tie Rod Assembly

May 5, 2006

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 & remedy

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.

06V144000 · Visibility:windshield Wiper/washer

Apr 28, 2006

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 & remedy

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.

03V434000 · Wheels

Nov 4, 2003

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

Consequence & remedy

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.

03V391000 · Seat Belts:rear/other

Oct 10, 2003

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 & remedy

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.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

PE10025 · Central Electronic Module Failure

Opened Jul 20, 2010 · Closed Nov 22, 2010

Status: closed (inferred from source dates) · Electrical System

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 injury associated with possible CEM failures have been reported by Volvo or otherwise identified by ODI.Volvo revised the design of the wiring grommet (sealing device) and the plenum cover starting in May 2005 and October 2005 production dates respectively, the occurrence of the condition effectively ended after these changes.A technical service bulletin (TNN 37-35) has been published to diagnose and repair earlier production vehicles using the improved wiring grommet and/or new plenum cover.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.

PE09039 · Fuel Pump Leak

Opened Aug 31, 2009 · Closed Dec 22, 2009

Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

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).

Additional source detail variants (4)

Fuel System, Gasoline:delivery:fuel Pump

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).

Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

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).

Fuel System, Gasoline:delivery

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).

Fuel System, Gasoline

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).

PE05064 · Windshield Wiper Arm Performance

Opened Dec 2, 2005 · Closed May 10, 2006

Status: closed (inferred from source dates) · Visibility:windshield Wiper/washer:linkages

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.