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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77,000 miles · Mar 11, 2011

Electrical System

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING APPROXIMATELY 40 MPH THE VEHICLE STALLED. THE CONTACT STATED THAT THE VEHICLE RESTARTED AFTER PULLING ONTO THE SIDE OF THE ROAD. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIANS WERE UNABLE TO DIAGNOSE THE FAILURE. THE TECHNICIANS PERFORMED UPDATES TO THE COMPUTER. THE VEHICLE WAS AT THE DEALERSHIP AND HAD NOT BEEN DRIVEN SINCE THE UPDATES WERE MADE. THE MANUFACTURER STATED THAT THE VIN WAS NOT INCLUDED IN ANY RECALLS AND REFERRED THE CONTACT TO THE DEALER FOR FURTHER QUESTIONS AND CONCERNS. THE APPROXIMATE FAILURE MILEAGE WAS 77,000.

NHTSA ODI #10389878

98,003 miles · Feb 16, 2011

Electrical System

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING APPROXIMATELY 60 MPH, THE VEHICLE JERKED VIOLENTLY AND THE INSTRUMENT PANEL GAUGES FAILED. THE ENGINE WAS SHUT OFF AND THEN RESTARTED AFTER SEVERAL MINUTES. THE VEHICLE RESUMED NORMALLY FOR A SHORT PERIOD BEFORE THE FAILURE RECURRED. THE CONTACT STATED THE MALFUNCTION OCCURRED AFTER DRIVING FOR APPROXIMATELY FIVE HOURS. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE FAULTY CEM UNIT WAS REPLACED. THE FAILURE MILEAGE WAS 98,003. UPDATED 3/21/11 *CN

NHTSA ODI #10382885

123,000 miles · Feb 15, 2011

Electrical System

CAR LOST ALL POWER. ALL DASHBOARD WENT OFF AND POWER STEERING WENT OUT WHILE DRIVING AT OVER 40 MILES AN HOUR ON THE HIGHWAY. THIS HAPPENED ON 4 DIFFERENT OCCASIONS. MILEAGE 123,000 2004 VOLVO XC90 T6. *TR

NHTSA ODI #10382839

108,540 miles · Jan 30, 2011

Electrical SystemPower TrainStructure

LIQUID (PROBABLY WATER) INSIDE THE FRAME OF VOLVO XC90 CAUSING ELECTRICAL ISSUES. *TR

NHTSA ODI #10379579

119,000 miles · Jan 13, 2011

Electrical SystemInjury

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT THE VEHICLE SHUT OFF AND BACK ON CAUSING A PAINFUL JERKING MOTION TO THE OCCUPANTS OF THE VEHICLE. THE CONTACT HURT HIS NECK AND SHOULDERS FROM THE DRASTIC JOLT THAT THE VEHICLE MADE. THE LIGHTS AND ALL POWER SHUT OFF AND THEN THEY IMMEDIATELY COME BACK ON. THE CONTACT HAD TAKEN THE VEHICLE TO THE DEALER SEVERAL TIMES AND WAS TOLD THAT THEY COULD NOT FIND ANYTHING WRONG WITH THE VEHICLE. THE CONTACT ALSO STATED THAT THE FAILURE SEEMED TO HAPPEN EVERY 500 MILES AND WAS NOW HAPPENING MORE FREQUENTLY. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 80,000 AND THE FAILURE MILEAGE WAS 119,000.

NHTSA ODI #10376565

115,089 miles · Dec 24, 2010

Electrical System

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DURING LONG DURATIONS(>4HRS) OF DRIVING MY 2004 VOLVO XC90, IT SEEMS TO HAVE ELECTRICAL PROBLEMS THAT HAVE CAUSED ME AND THE PASSENGERS TO BE PUT INTO DANGEROUS SITUATIONS. FOR EXAMPLE, DRIVING ON A LONG TRIP WITH THE CRUISE CONTROL ENABLED AND TRYING TO ACCELERATE UP A HILL AND SUDDENLY THE CAR WILL GO INTO AN ENGINE PROTECTION MODE AND REDUCE POWER TO THE EXTENT THAT I CAN'T ACCELERATE AND HAVE TO PULL OVER ON THE SIDE OF THE ROAD--(BOOST CONTROL MODULE HAS BEEN REPLACED AND THE ENGINE CONTROL MODULE HAS BEEN REPLACED.) AS LONG AS I DON'T USE THE CRUISE CONTROL THIS WILL NOT OCCUR. ALSO, THERE WAS A SOFTWARE UPDATE IN 2009. NEXT, AFTER TRYING TO ACCELERATE UP A HILL, THERE SEEMS TO BE INTERMITTENT REDUCTION IN ENGINE POWER, NOT ALLOWING THE CAR TO ACCELERATE. AFTER TRYING TO ACCELERATE THE "CHECK ENGINE" LIGHT HAS APPEARED AND WILL NOT GO OFF (WAITING TO HAVE THIS PROBLEM DIAGNOSED)... *TR

NHTSA ODI #10372343

132,000 miles · Nov 17, 2010

Electrical System

TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT WHILE DRIVING 65 MPH, EVERY ELECTRICAL COMPONENT MALFUNCTIONED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE STEREO SYSTEM NEEDED TO BE REPLACED; THE VEHICLE WAS REPAIRED. TWO DAYS AFTER THE REPAIR, THE ELECTRICAL SYSTEM MALFUNCTIONED AGAIN. THE …

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NHTSA ODI #10366551

10,000 miles · Nov 10, 2010

Electrical SystemEquipment

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT THE OWNER'S MANUAL PROVIDED INACCURATE INFORMATION PERTAINING TO THE TOWING CAPACITY; HOWEVER, THE 2005 AND 2006 OWNER'S MANUAL SPECIFIED THE ACCURATE WEIGHT REDUCTION WITH THE VEHICLE OCCUPANTS. IN ADDITION, THE ENTIRE ELECTRICAL SYSTEM BECAME INOPERATIVE INTERMITTENTLY. THE RELAY SWITCH, INTERNAL REM AND YAW MODULES WERE REPLACED AT DIFFERENT TIMES. WHILE DRIVING THE ENGINE WOULD COMPLETELY SHUT OFF WHEN THE CONTACTS KNEE WAS CLOSE TO THE IGNITION KEY. THE FAILURE CONTINUED AFTER THE VEHICLE WAS REPAIRED. CURRENTLY, DIAGNOSTIC TESTING WAS BEING PERFORMED BY THE DEALER. THE FAILURE MILEAGE WAS 10,000.

NHTSA ODI #10365255

83,000 miles · Nov 7, 2010

Electrical System

MULTIPLE ELECTRICAL SYSTEM PROBLEMS WITH MOST RECENT BEING A SHUTDOWN EVERYTHING ELECTRICAL ON THE DASHBOARD. CAR WOULD STILL DRIVE BUT NO INSTRUMENTATION, DOOR LOCKS, WINDOWS OR ABILITY TO OPEN GAS TANK COVER FROM BUTTON INSIDE CAR. *TR

NHTSA ODI #10364361

69,000 miles · Oct 22, 2010

Electrical System

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2004 VOLVO XC 90 , 2.5 AWD. WHILE DRIVING ON I40 AT NIGHT ,(65 MPH, IN DRIVE) A LOUD THUMP FOLLOWED BY MOMENTARY ELECTRICAL FAILURE( HEADLIGHTS, LOSS OF ENGINE POWER.) IT THEN PICKED BACK UP AND CONTINUED ON FOR APPROX 1/4 MILE AND IT HAPPENED AGAIN. MADE INTO FAR RIGHT LANE FROM THE 3RD LANE OVER. OTHER THAN THE RADIO VOLUME EVERYTHING WORKED AS NORMAL THE NEXT 40 MILES TO HOME. THIS HAPPENED AT APPROX. 9:30 PM IN THE MIDDLE OF THE INTERSTATE . WHAT IF THE LIGHTS HAD FAILED AND IT NOT REGAINED POWER, 40/85 IS A BUSY HIGHWAY AT NIGHT. I WAS DRIVING WITH MY WIFE AND 2 KIDS. *TR

NHTSA ODI #10361699

Official recalls

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

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

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

Fuel System, Gasoline:delivery

Fuel System, Gasoline

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.