Fuel line was recalled in 2010. Volvo repaired it now it has the same problem. And is leaking fuel. Same line that they replaced in 2010. Please recall.
2003 Volvo XC90
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2003 Volvo XC90 do not stand out strongly from the model-year median of 34.
About this comparison →How this year compares
Owner complaints by model year
Compare all XC90 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
79 reports with mileage · 14 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.
- Power Train. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 18 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 9 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
93 reportsTRANSFER CASE KEEPS LOCKING UP AND MESSING UP. IN PAST YEAR PAID 1500 TWO TIMES TO REPLACE TRANSFER CASE AND IS NOW IN SHOP AGAIN FOR SAME REASON. TRANSFER CASE LOCKING UP. FEB 2020, JULY 2020, AND NOW JANUARY 2021 FEB GOING SPEED OF 35-40, JULY ON HIGHWAY SPEED OF 70 IN MIDDLE OF FREEWAY, AND JAN SPEED OF 35
DRIVING THE XC90 AND SUDDENLY THERE IS A HUGE THUMP AND CLICKING FROM THE DASHBOARD. ALL THE DIALS AROUND THE SPEDOMETER STOP WORKING.. IF WE KEEP DRIVING THERE ARE MORE THUMPS AND WE QUICKLY LOSE ENGINE POWER - IT IS EXTREMELY SCARY WHEN IT HAPPENS.. ALL THE LIGHTS COME ON (INSIDE THE CAR), DASHBOARD GOES DEAD ETC ETC. IT IS…
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DRIVING THE XC90 AND SUDDENLY THERE IS A HUGE THUMP AND CLICKING FROM THE DASHBOARD. ALL THE DIALS AROUND THE SPEDOMETER STOP WORKING.. IF WE KEEP DRIVING THERE ARE MORE THUMPS AND WE QUICKLY LOSE ENGINE POWER - IT IS EXTREMELY SCARY WHEN IT HAPPENS.. ALL THE LIGHTS COME ON (INSIDE THE CAR), DASHBOARD GOES DEAD ETC ETC. IT IS EXTREMELY DANGEROUS .. IT HAPPENED TO USE A NUMBER OF TIMES WITH 3 CHILDREN IN THE CAR. IT HAS OCCURRED WHEN WE WERE DRIVING ON THE HIGHWAY, 2-3 TIMES, IT HAS OCCURRED ON SHORT TRIPS - IT HAPPENS AT SEEMINGLY RANDOM TIMES, USUALLY AFTER DRIVING FOR OVER 30 MINUTES, BUT THEN YESTERDAY IT HAPPENED ON A TRIP JUST DOWN TO THE PARK, NOT 5 MINUTES DOWN THE ROAD.. ON THIS OCCASION THE CAR HAD BEEN SITTING IN THE SUN FOR A WHILE (MAYBE HEAT RELATED?). IT HAS HAPPENED IN HOT WEATHER, COLD WEATHER .. WE ARE IN CONSTANT FEAR WHEN DRIVING THE CAR. I HAVE CONTACTED VOLVO AUSTRALIA ABOUT THE ISSUE BUT THEY SAID THEY HAVE NO RESPONSIBILITY, THAT THERE IS NO RECALL FOR THE PROBLEM AND DIDN'T WANT TO HELP AT ALL!! I SEE A LOT OF PEOPLE HAVE THIS SAME PROBLEM, IS VOLVO NOT GOING TO FIX IT UNTIL SOMEONE IS KILLED??? WHAT WILL IT TAKE!?!?!?! IT IS A JOKE ! WE BOUGHT A VOLVO TO HAVE SOMETHING SAFER THAN NORMAL BUT ITS MORE DANGEROUS! I CANNOT EVEN SELL THE CAR BECAUSE I DON'T KNOW WHAT'S WRONG WITH IT AND I DON'T WANT ANOTHER FAMILY / PERSON TO BE INJURED .. NO RESALE VALUE, NO SAFETY! COME ON VOLVO, THIS IS CRAZY!
WHEN THIS VEHICLE WAS PURCHASED IT STARTED WITHIN 4 DAYS TO HAVE PROBLEMS WITH THE TRANSMISSION, AFTER THE TRANSMISSION THE TRANSFER CASE BEGAN TO HAVE PROBLEMS, SO THE VEHICLE WAS PLACED IN THE SHOP BEFORE THE THIRTY DAYS TAGS COULD EXPIRE AND BOTH PARTS WERE REBUILT BY AN OUTSIDE COMPANY WHICH WAS ADDED TO THE ORIGINAL PRICE …
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WHEN THIS VEHICLE WAS PURCHASED IT STARTED WITHIN 4 DAYS TO HAVE PROBLEMS WITH THE TRANSMISSION, AFTER THE TRANSMISSION THE TRANSFER CASE BEGAN TO HAVE PROBLEMS, SO THE VEHICLE WAS PLACED IN THE SHOP BEFORE THE THIRTY DAYS TAGS COULD EXPIRE AND BOTH PARTS WERE REBUILT BY AN OUTSIDE COMPANY WHICH WAS ADDED TO THE ORIGINAL PRICE TAG OF THE VEHICLE. THEN A YEAR LATER THE VEHICLE WAS PLACED IN THE SHOP FOR THE TURBO'S HAD GONE OUT ON THE VEHICLE ON APRIL 11, 2015 UNTIL CURRENT DATE. THEY ARE NOW SAYING THE VEHICLE HAS A BLOWN HEAD GASKET AND IT IS STILL IN THE SHOP.
VEHICLE DRAINS WATER ON TO FRONT PASSENGER FLOOR, AND OCASSIONAL DRIVER SIDE AFTER IT RAINS. IT IS A KNOW PROBLEM THAT A CLASS ACTION SUIT WAS WON IN NEW JERSEY, INCLUDING 5 OTHER STATES. THE WATER IS FROM CLOGGED DRAIN TUBES IN SUNROOF AND SOMETIMES SHRINKIAGE OF DRAIN TUBE THAT DISLODGES. VEHICLE NOW HAS A MUSTY SMELL FROM THE…
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VEHICLE DRAINS WATER ON TO FRONT PASSENGER FLOOR, AND OCASSIONAL DRIVER SIDE AFTER IT RAINS. IT IS A KNOW PROBLEM THAT A CLASS ACTION SUIT WAS WON IN NEW JERSEY, INCLUDING 5 OTHER STATES. THE WATER IS FROM CLOGGED DRAIN TUBES IN SUNROOF AND SOMETIMES SHRINKIAGE OF DRAIN TUBE THAT DISLODGES. VEHICLE NOW HAS A MUSTY SMELL FROM THE FREQUENT WATER IN THE VEHICLE. NOT SURE IF HIGH MOISTURE INSIDE HAS CAUSED MY CD PLAYER TO MALFUNCTION. ALSO HAVE A SHORT IN ELECTRICAL SYSTEM THAT CAUSE ME TO REPLACE 3 BATTERIES IN THE VEHICLE. ALSO THE SUNROOF MOTOR SHORTED OUT MAKING IT DIFFICULT TO REPLACE THE DRAINAGE TUBES THAT WOULD HELP CORRECT THE WATER ISSUES. HOPE SOMEONE CAN HELP.
TL* THE CONTACT OWNS A 2003 VOLVO XC90. WHILE DRIVING AT APPROXIMATELY 55 MPH, FUEL FUMES EMITTED INTO THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT FUEL WAS ALL OVER THE EXHAUST PIPE AND THE BOTTOM OF THE FUEL TANK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP…
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TL* THE CONTACT OWNS A 2003 VOLVO XC90. WHILE DRIVING AT APPROXIMATELY 55 MPH, FUEL FUMES EMITTED INTO THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT FUEL WAS ALL OVER THE EXHAUST PIPE AND THE BOTTOM OF THE FUEL TANK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP WAS CRACK AND LEAKING FUEL. THE VEHICLE WAS NOT REPAIRED. THE VIN NUMBER WAS NOT INCLUDED IN NHTSA CAMPAIGN: 09V483000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 111,000.
TL* THE CONTACT OWNS A 2003 VOLVO XC90. THE CONTACT STATED THAT FUEL FUMES EMITTED IN AND AROUND THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE TECHNICIAN DIAGNOSED THAT THERE WAS A LEAK IN THE FUEL PUMP. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND CONFIRMED THAT THE VIN WAS NOT …
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TL* THE CONTACT OWNS A 2003 VOLVO XC90. THE CONTACT STATED THAT FUEL FUMES EMITTED IN AND AROUND THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE TECHNICIAN DIAGNOSED THAT THERE WAS A LEAK IN THE FUEL PUMP. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND CONFIRMED THAT THE VIN WAS NOT ASSOCIATED WITH NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 141,000.
TRANSMISSION FAILED WITHOUT WARNING. HERE'S THE STORY, MY XC90 WAS DEALER SERVICED A WEEK AGO (PM), TOOK ON A SHORT ROAD TRIP OVER WEEKEND, FORTUNATELY MADE IT HOME BEFORE IT BROKE DOWN. WENT TO WORK UPON RETURNING FROM TRIP AND WHILE I WAS PARKING THE TRANSMISSION FAILED TO ENGAGE IN ANY GEAR. VERY UNSAFE! NO WARNING LIGHTS ILL…
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TRANSMISSION FAILED WITHOUT WARNING. HERE'S THE STORY, MY XC90 WAS DEALER SERVICED A WEEK AGO (PM), TOOK ON A SHORT ROAD TRIP OVER WEEKEND, FORTUNATELY MADE IT HOME BEFORE IT BROKE DOWN. WENT TO WORK UPON RETURNING FROM TRIP AND WHILE I WAS PARKING THE TRANSMISSION FAILED TO ENGAGE IN ANY GEAR. VERY UNSAFE! NO WARNING LIGHTS ILLUMINATED AND THERE WAS NO 'LIMP MODE.' THE RPMS ROSE AS IF IT WERE IN NEUTRAL. COULD HEAR A METALLIC RATTLING NOISE COMING FROM TRANSMISSION. HAD TO HAVE IT TOWED FROM WORK TO AAMCO. AAMCO STATED THE DAMAGE WAS INSIDE OF TRANSMISSION AND THEY WOULD NEED TO REMOVE AND TEAR DOWN TO SEE WHAT ISSUE IS, BUT MORE THAN LIKELY IT WAS A COMPLETE FAILURE. I JUST BOUGHT THIS CAR IN NOVEMBER AND LUCKILY BOUGHT AN AFTERMARKET WARRANTY THAT 'SHOULD' COVER EVERYTHING. ISSUE IS THE WARRANTY COMPANY WILL MORE THAN LIKELY JUST REPLACE IT WITH A USED TRANS THAT WILL FAIL IN A SHORT TIME AND I WILL HAVE TO GO THROUGH THIS AGAIN. THIS IS A MAJOR DESIGN FLAW ON THE PART OF VOLVO AND THEY SHOULD OWN UP TO IT. THE ENGINE PRODUCES TOO MUCH POWER AND THE VEHICLE IS TOO HEAVY FOR THE TRANSMISSION TO TAKE IT. THIS IS A T6 BTW, WITH THE 6 CYLINDER AND TWIN TURBO. VOLVO SHOULD HAVE A RECALL ON THIS TRANSMISSION. I HAVE SCOURED THE WEB AND SEE THIS IS AN ONGOING FREQUENT ISSUE WITH THE XC90 AND VOLVO IS LOSING WHAT WERE ONCE LOYAL CUSTOMERS. SEARCH THIS ISSUE ON THE WEB AND YOU'LL WONDER IF THERE ARE ANY XC90'S THAT DO NOT HAVE TRANSMISSION PROBLEMS. *TR
TL* THE CONTACT OWNS A 2003 VOLVO XC90. THE CONTACT STATED THAT GASOLINE FUMES WERE EMITTED INTO THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THERE WAS A LEAK IN THE FUEL PUMP AND IT NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE SINCE THE…
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TL* THE CONTACT OWNS A 2003 VOLVO XC90. THE CONTACT STATED THAT GASOLINE FUMES WERE EMITTED INTO THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THERE WAS A LEAK IN THE FUEL PUMP AND IT NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN NHTSA RECALL CAMPAIGN 09V483000 (FUEL SYSTEM). THE VEHICLE WAS REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 108,000. THE CURRENT MILEAGE WAS 109,000.
FUEL FUMES PRESENT WHEN THE CAR WAS TURNED OFF. MORE PRONOUNCED IN PARKING AND HOME GARAGES. DAILY HIGHWAY DRIVING (55 MILES ONE WAY) MAY BE RELATED TO RECALL OF XC 90 IN WARM STATES AS HIGHWAY MILEAGE SIMILAR IN NATURE. *TR
Official recalls
510V566000 · 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.
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
0No exact-year investigations in this snapshot.
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