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

Power Train complaints

145 reports

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80,512 miles · Aug 3, 2008

Power Train

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MY 2004 VOLVO XC90 T6 HAS HAD SEVERAL RIDICULOUS ISSUES THAT I HAVE NEVER EXPERIENCED IN ANY OF THE GERMAN VEHICLES I HAVE OWNED OVER THE PAST 20 YEARS. I HAVE BEEN FEARFUL OF THIS CAR OF LATE MAINLY BECAUSE I READ SEVERAL COMPLAINTS ABOUT THE RELIABILITY OF THE TRANSMISSION ON THIS VEHICLE. WELL MY FEARS BECAME REALITY ON FRIDAY NIGHT WHILE MY WIFE AND 22 MONTH SON WERE COMING HOME FROM THE MARKET. MY WIFE CALLED ME FRANTIC ABOUT HOW THE CAR WILL NOT GO INTO REVERSE AND NOW THAT I HAVE MANAGED TO DRIVE OUT OF MY PARKING SPOT IT IS NOT MOVING ABOVE 20 MPH. NEEDLESS TO SAY, I WAS ANGRY AND VERY CONCERNED FOR MY FAMILY'S SAFETY. SHE WAS ABLE TO CREEP HOME AND WE CALLED THE TOW TRUCK COMPANY TO TAKE THIS PIECE OF JUNK TO MOOER'S VOLVO IN RICHMOND VIRGINIA 804 755-666. I WISH TO FILE A COMPLAINT ABOUT THE RELIABILITY OF THIS VEHICLE AND THE DANGER IT PLACES IT'S OWNERS (MOSTLY PEOPLE WHO TURN TO VOLVO DUE TO IT'S SAFETY RECORD, WE SURE DID!) AND THEIR FAMILIES. I HAVE READ HUNDREDS OF PEOPLE EXPERIENCING THIS EXACT PROBLEM WITH THIS VEHICLE. THE DEALERS KNOW THERE ARE ISSUES WITH THESE CARS YET THEY DUMB YOU DOWN AS IF YOU ARE A UNIQUE CASE. MONDAY MORNING I WILL BE IN MY ATTORNEY'S OFFICE WITH MY FACTS I GATHERED OVER THE WEEKEND SHOWING THIS IS SUCH A RIDICULOUSLY COMMON PROBLEM THAT IF VOLVO HASN'T DONE RIGHT BY CONSUMERS THEY BETTER GET READY FOR MAJOR LAWSUITS. TO START, THEY NEED TO BUY THESE CARS BACK FROM CONSUMERS FOR WHAT EVER THEY OWE ON THESE CARS AND ISSUE A STATEMENT APOLOGIZING FOR PUTTING OUT SUCH A TERRIBLY DANGEROUS PRODUCT FOR FAMILIES. *TR

NHTSA ODI #10236786

56,000 miles · Aug 2, 2008

Engine And Engine CoolingPower TrainWheels

TRANSMISSION FAILURE ON OUR 2004 VOLVO XC-90 T6 AWD AT APPROXIMATELY 56,000K MILES. FORTUNATELY IT WAS A WARRANTY REPAIR; HOWEVER MY RESEARCH ON AUTOMOTIVE DISCUSSION BOARDS LIKE EDUMDS INDICATES A VERY LARGE PATTERN OF FAILURE OF THE TRANSMISSION ON THIS MODEL. *TR

NHTSA ODI #10236706

75,000 miles · Aug 1, 2008

Power Train

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED THAT HE EXPERIENCED TONS OF FAILURES WITH THE VEHICLE. THE RACK AND PINION WAS REPLACED AT 52,000 MILES. THE STRUTS FAILED ON THE REAR OF THE VEHICLE AND THE DEALER HAD TO REPAIR THE U JOINT. WHILE DRIVING 60 MPH, THE VEHICLE WOULD NOT SHIFT GEARS AND THE DEALER STATED THAT A NEW TRANSMISSION WAS NEEDED. LATER, THE CONTACT DISCOVERED HUNDREDS OF COMPLAINTS IN REGARDS TO THE SAME YEAR, MAKE, AND MODEL VEHICLE. THE SEALS FOR THE POWER TRANSFER UNIT FAILED. RECENTLY, THE ENTIRE THERMOSTAT UNIT HAD TO BE REPLACED AND THE TRANSMISSION FAILED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 75,000 AND CURRENT MILEAGE WAS 76,500.

NHTSA ODI #10236659

71,000 miles · Jul 21, 2008

Power Train

MY 2004 VOLVO XC90 T6 HAS PRODUCED A "TRANSMISSION SERVICE URGENT" MESSAGE BUT THE DEALER COULD NOT FIND A PROBLEM IN THE VEHICLE MEMORY. IT INTERMITTENTLY WOULD REV OVER 3K RPM WITH NO ACCELERATION AND WOULD VIOLENTLY JERK INTO GEAR FROM A STOP AFTER REVVING FOR A FEW SECONDS WITHOUT ACCELERATION. JUST BEFORE THE DEALER FINAL…

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NHTSA ODI #10235223

62,000 miles · Jul 21, 2008

Power Train

THE GEARS STARTED SLIPPING . I BROUGHT INTO VOLVO DEALERSHIP AND THEY SAY I NEED A NEW TRANSMISSION. AFTER READING UP ON INTERNET THIS IS A PROBLEM ALOT OF PEOPLE ARE HAVING. TRANSMISSIONS SHOULD NOT FAIL AT 60, 000 MILES. *TR

NHTSA ODI #10235186

70,000 miles · Jul 21, 2008

Power Train

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VEHICLE UNABLE TO SHIFT PROPERLY, COMPUTER READING "TRANSMISSION URGENT SERVICE" LOCKS IN THIRD GEAR IN "LIMP MODE". VEHICLE CAUSED VERY NEAR FATAL ACCIDENT WHEN STOPPED ON A HILL AND AFTER INITIALLY MOVING OUT INTO TRAFFIC, SEIZED TO OPERATE. TOWED TO DEALER, DEALER FIRST FLUSHED OUT TRANSMISSION AT $240.00, THEN WITHOUT ROAD TESTING, SUGGESTED WE TRY AGAIN. VEHICLE FAILED ONCE AGAIN WHILE IN THE DEALERSHIP PARKING LOT AND WAS TOLD THE TRANSMISSION NEEDED TO BE REPLACED, $6,000 LATER. *TR

NHTSA ODI #10235154

64,000 miles · Jul 14, 2008

Power Train

2004 VOLVO XC90 T6: TRANSMISSION FAILURE AT 64,000 MILES. OTHER ISSUES: BRAKES EVERY 1.5YRS (15,000 MILES); TIRES EVERY TWO YEARS (20,000 MILES). *TR

NHTSA ODI #10234330

92,000 miles · Jul 11, 2008

Power Train

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WHILE DRIVING ON THE INTERSTATE HIGHWAY, THE 'TRANSMISSION SERVICE URGENT' MESSAGE APPEARED ON THE DISPLAY OF MY 2004 VOLVO XC90. I WAS FORTUNATELY ABLE TO DRIVE THE CAR HOME (<1 MILE) AND GET IT TO A VOLVO SERVICE CENTER (20 MILES) THE FOLLOWING MORNING. THE SERVICE CENTER INDICATED THAT 3RD GEAR OF OUR AUTOMATIC TRANSMISSION WAS 'GONE' AND THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE TRANSMISSION WAS REPLACED WITH A RE-MANUFACTURED TRANSMISSION. I FOUND THIS ISSUE SURPRISING SINCE, ALTHOUGH THIS VEHICLE HAS SIGNIFICANT MILEAGE FOR ITS AGE, >90% OF THAT MILEAGE CAN BE ATTRIBUTED TO HIGHWAY DRIVING (COMMUTE >80 MILES PER DAY). I ALSO HAVE REVIEWED MANY REPORTS ONLINE FROM OTHER VOLVO XC90 VEHICLE OWNERS DESCRIBING THE SAME PROBLEM AT FAR LOWER MILEAGE. *TR

NHTSA ODI #10234004

94,462 miles · Jul 9, 2008

Power Train

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MY CAR IS NOT DRIVING WELL WHEN I DRIVE IT HESITATES WHICH IS VERY DANGEROUS WHEN I DRIVING ESPECIALLY ON THE HIGHWAY I JUST RECENTLY NOTICED THAT THE TRANSMISSION LIGHT CAME ON, AND WHEN I BROUGHT IT TO BE SERVICE THE SAID IT IS GOING TO BE $2,500 I JUST HAD IT SERVICED IT HAS 94,000 MILES ON IT BUT WHEN I CHECKED ONLINE I SEE THAT OTHERS WITH LESS MILES HAVE THE SAME COMPLAINT WITH LESS MILES. WE PAY ALOT FOR GREAT QUALITY AND SAFETY FOR OUR FAMILIES. SO THERE SHOULD BE A RECALL CAUSE I'M NOT THE ONLY ONE. *TR

NHTSA ODI #10233704

60,000 miles · Jun 25, 2008

Power Train

TRANSMISSION COMPLAINT FOR VOLVO XC90 T6 2004. DEALERSHIP SAYING TRANSMISSION NEEDS TO BE REPLACED. VEHICLE IS ONLY AT 60,000 MILES. MANY OTHER CONSUMERS DEALING WITH THE SAME ISSUE. *TR

NHTSA ODI #10232285

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.