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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.

About this comparison →

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

Steering complaints

20 reports
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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

76,000 miles · Sep 15, 2008
Engine And Engine CoolingPower TrainSteering

TRANSMISSION REPLACED JUNE 08 FRONT CONTROL ARMS AND BUSHINGS AND COOLANT RESERVOIR REPLACED SEPT. 08 THERMOSTAT & HOUSING & TEMP SENSOR REPLACED JAN. 08 BRAKE VACUUM PUMP REPLACED FOR 2ND TIME JAN. 08 BRAKE VACUUM PUMP REPLACED SEPT. 07 GASKET, O-RING, HOSE CLAMP RECALL SEPT. 07 POWER STEERING PUMP AND BRAKE VACUUM PUMP I…

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TRANSMISSION REPLACED JUNE 08 FRONT CONTROL ARMS AND BUSHINGS AND COOLANT RESERVOIR REPLACED SEPT. 08 THERMOSTAT & HOUSING & TEMP SENSOR REPLACED JAN. 08 BRAKE VACUUM PUMP REPLACED FOR 2ND TIME JAN. 08 BRAKE VACUUM PUMP REPLACED SEPT. 07 GASKET, O-RING, HOSE CLAMP RECALL SEPT. 07 POWER STEERING PUMP AND BRAKE VACUUM PUMP INSTALLED JULY 07 STEERING RACK SOLENOID REPLACED JULY 07 - (RECALL MAY 3, 08?) NEW BRIDGESTONE TIRES MAY 07 UPPER ENGINE TORQUES MOUNT REPLACED MARCH 07 RECALL WIPER ARM 156, BALL JOINT 157 OCT. 06 BRAKE PAD & ROTORS REPLACED OCT 06 UPGRADE SOFTWARE A & C JULY 05 ABS BRAKES WARRANTY FIX MAY 06 FRONT PADS & REAR PADS & ROTORS REPLACED DEC. 05 EXHAUST RUBBING ON DRIVELINE, INSTALL KIT TO HOLD EXHAUST OFF DRIVELINE DEC. 05 LEFT REAR WHEEL BEARING & HUB, REAR PADS & ROTORS REPLACED JUNE 05 4 NEW TIRES JUNE 05 TURBO CONTROL VALVE REPLACED MARCH 05 FRONT PADS AND ROTORS REPLACED OCT. 04. *TR

NHTSA ODI #10242337

60,000 miles · Sep 11, 2008
Air BagsElectrical SystemExterior Lighting

WHILE DRIVING MY 2004 VOLVO XC-90 AT NIGHT I EXPERIENCED A MOMENTARY LOSS OF CONTROL, FOLLOWED BY THE HEADLIGHTS PAUSING AND THEN GOING FROM HIGH BEAMS TO LOW. THE INSTRUMENT CLUSTER LOST SOME OF IT'S DISPLAYS AND THE DOOR LOCKS BECAME INOPERATIVE. THE DATA DISPLAY WARNED ME OF AN "URGENT SRS FAILURE". I WAS AT LOW SPEED A BLOC…

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WHILE DRIVING MY 2004 VOLVO XC-90 AT NIGHT I EXPERIENCED A MOMENTARY LOSS OF CONTROL, FOLLOWED BY THE HEADLIGHTS PAUSING AND THEN GOING FROM HIGH BEAMS TO LOW. THE INSTRUMENT CLUSTER LOST SOME OF IT'S DISPLAYS AND THE DOOR LOCKS BECAME INOPERATIVE. THE DATA DISPLAY WARNED ME OF AN "URGENT SRS FAILURE". I WAS AT LOW SPEED A BLOCK FROM HOME SO I CREPT HOME AND THE NEXT DAY SENT THE CAR TO TRIAD VOLVO BY ROLL-BACK WRECKER. PROBLEM WAS FAILURE OF CENTRAL ELECTRONIC MODULE. I CALLED VOLVO CORPORATE AND THEY SEEMED DISINTERESTED. *TR

NHTSA ODI #10241888

23,000 miles · May 20, 2008
Steering

TL*THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT ANY SPEED, THE STEERING COLUMN MAKES A KNOCKING NOISE WHEN IT IS TURNED. THE CONTACT DID NOT NOTICE ANY DIFFERENCES IN THE VEHICLE PRIOR TO THE FAILURE. THE VEHICLE HAS BEEN DIAGNOSED BY THE DEALER SEVERAL TIMES, BUT THE FAILURE STILL PERSISTS. THE CURRENT MILEAGE IS 77…

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING AT ANY SPEED, THE STEERING COLUMN MAKES A KNOCKING NOISE WHEN IT IS TURNED. THE CONTACT DID NOT NOTICE ANY DIFFERENCES IN THE VEHICLE PRIOR TO THE FAILURE. THE VEHICLE HAS BEEN DIAGNOSED BY THE DEALER SEVERAL TIMES, BUT THE FAILURE STILL PERSISTS. THE CURRENT MILEAGE IS 77,000 AND FAILURE MILEAGE WAS 23,000. UPDATED 6/9/08 *CN THE VEHICLE ALSO HAD A POWER STEERING LEAK.

NHTSA ODI #10228335

10 miles · Oct 24, 2007
Steering

STEERING FEELS SLOPPY AND CAR PULLS TO THE LEFT. DEALER SENT IT FOR ALIGNMENT FOR MORE THAT 10 TIMES. PROBLEM NOT RECTIFIED. DEALER ALSO REPLACED THE FLANGE NUT IN THE STEERING WHEEL BUT FEELS STILL SLOPPY. *TR

NHTSA ODI #10206835

9,750 miles · Oct 9, 2007
Electrical SystemExterior LightingSeat Belts

UNSAFE FRONT SUSPENSION REPAIRED 4 TIMES BY VOLVO INVOLVING DISTRICT FACTORY TECHNICAL SUPERVISOR AND TECHNICIANS ON 3 OF FOUR OCCASIONS AND THE VEHICLE STILL HAS SERIOUS SAFETY AND HANDLING CONCERNS - NO ONE IN THE FAMILY WILL DRIVE THE CAR. IT HAS ALSO HAD SERIOUS PERFORMANCE RELATED SAFETY ISSUES REGARDING VEHICLE ELECTRONICS…

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UNSAFE FRONT SUSPENSION REPAIRED 4 TIMES BY VOLVO INVOLVING DISTRICT FACTORY TECHNICAL SUPERVISOR AND TECHNICIANS ON 3 OF FOUR OCCASIONS AND THE VEHICLE STILL HAS SERIOUS SAFETY AND HANDLING CONCERNS - NO ONE IN THE FAMILY WILL DRIVE THE CAR. IT HAS ALSO HAD SERIOUS PERFORMANCE RELATED SAFETY ISSUES REGARDING VEHICLE ELECTRONICS VIRTUALLY SHUTTING THE VEHICLE DOWN IN THE MIDDLE OF AN INTERSTATE. ANTI SKID PROBLEMS ON MULTIPLE OCCASIONS. DRIVERS SEAT BELT ANCHOR WAS IMPROPERLY ATTACHED AND WOULD NOT HAVE HELD IN AN ACCIDENT. THE STEERING WHEEL CAME DANGEROUSLY LOOSE WHILE DRIVING AND THE DEALERSHIP STATED THAT IT HAD NEVER BEEN PROPERLY AFFIXED. (I HAVE OWNED 300 CARS IN MY LIFE AND NEVER HAS A STEERING WHEEL COME LOOSE)! TIRES WERE ABNORMALLY BADLY AND QUICKLY DUE TO SIGNIFICANT SUSPENSION PROBLEMS AND WERE NOT WARRANTY BY THE MANUFACTURE.. ELECTRICAL PROBLEMS CAUSED SEVERAL FUSES TO BLOW IN THE DARK EFFECTIVELY TURNING ALL REAR MARKER AND TAIL LIGHTS OFF. IT WAS NECESSARY TO DRIVE WITH THE HAZARD LIGHTS ON TO AVOID BEING HIT BY ANOTHER DRIVER. *TR

NHTSA ODI #10205276

Mileage unknown · Aug 16, 2006
Steering

2004 VOLVO XC90 FRONT RIGHT TIRE BECAME DISCONNECTED FROM THE AXLE AND COLLAPSED UNDER THE VEHICLE. UPON INSPECTION MECHANIC DETERMINED THAT THE TIE ROD SNAPPED IN HALF. *KB THE VEHICLE WAS TOWED TO A DEALER AND THE TECHNICIAN FOUND OUT THAT THERE HAD BEEN A RECALL ON THE TIE ROD (RECALL 06V155000). THE TIRE RODS WERE REPLAC…

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2004 VOLVO XC90 FRONT RIGHT TIRE BECAME DISCONNECTED FROM THE AXLE AND COLLAPSED UNDER THE VEHICLE. UPON INSPECTION MECHANIC DETERMINED THAT THE TIE ROD SNAPPED IN HALF. *KB THE VEHICLE WAS TOWED TO A DEALER AND THE TECHNICIAN FOUND OUT THAT THERE HAD BEEN A RECALL ON THE TIE ROD (RECALL 06V155000). THE TIRE RODS WERE REPLACED ON BOTH SIDE UNDER THE RECALL. *NM

NHTSA ODI #10165879

28,398 miles · Jun 13, 2006
SteeringSuspension

THE FRONT END TIE ROD BROKE SUDDENLY ON OUR 2004 VOLVO XC90 BRINGING THE CAR TO A COMPLETE HALT JUST AFTER MY SON HAD PULLED ON TO THE EXIT RAMP AFTER DRIVING 35 MILES ON A MAJOR 6 LANE HIGHWAY IN NEW JERSEY. WE WERE SOOOO LUCKY. VOLVO REPLACED BOTH FRONT END TIE RODS WITH WHAT THEY CLAIM TO BE A NEW AND IMPROVED TIE ROD. WE…

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THE FRONT END TIE ROD BROKE SUDDENLY ON OUR 2004 VOLVO XC90 BRINGING THE CAR TO A COMPLETE HALT JUST AFTER MY SON HAD PULLED ON TO THE EXIT RAMP AFTER DRIVING 35 MILES ON A MAJOR 6 LANE HIGHWAY IN NEW JERSEY. WE WERE SOOOO LUCKY. VOLVO REPLACED BOTH FRONT END TIE RODS WITH WHAT THEY CLAIM TO BE A NEW AND IMPROVED TIE ROD. WE STILL QUESTION THE SAFETY OF THE CAR AT THIS POINT AND WILL NOT ALLOW OUR TEENAGERS TO DRIVE IT ON THE HIGHWAY. VOLVO USA HAS BEEN ANTAGONISTIC WITH US ABOUT TAKING BACK THE CAR BUT OUR LOCAL DEALER IS WILLING TO TRADE IT FOR ANOTHER VOLVO. *JB

NHTSA ODI #10159755

1,000 miles · Nov 17, 2004
Electrical SystemSteeringSuspension

I HAVE HAD NUMEROUS FAILURES WITH MY 1990 VOLVO: I AM ON MY THIRD SET OF TIRES, AND I HAVE 30,000 MILES. I HAVE HAD SEVERAL SHOCK ABSORBERS REPLACED ,A TIE ROD BREAK, AND MANY ELECTRICAL PROBLEMS. *AK

NHTSA ODI #10100120

Mileage unknown · Sep 13, 2004
Air BagsElectrical SystemSteering

ON AUGUST, 26, 2004 THERE WAS A MAJOR MALFUNCTION IN OUR VOLVO XC90 (2004). WHILE DRIVING WITH 2 SMALL CHILDREN IN CAR SEATS AND 2 ADULTS ON A MAJOR HIGHWAY; SUDDENDLY, THERE WAS NO ACCELERATION IN THE GAS PEDAL AND THE STEARING WHEEL DID NOT FUNCTION. WE MANAGED TO SLOWLY MOVE TO THE SIDE OF THE ROAD FROM WHAT MOMENTUM WAS…

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ON AUGUST, 26, 2004 THERE WAS A MAJOR MALFUNCTION IN OUR VOLVO XC90 (2004). WHILE DRIVING WITH 2 SMALL CHILDREN IN CAR SEATS AND 2 ADULTS ON A MAJOR HIGHWAY; SUDDENDLY, THERE WAS NO ACCELERATION IN THE GAS PEDAL AND THE STEARING WHEEL DID NOT FUNCTION. WE MANAGED TO SLOWLY MOVE TO THE SIDE OF THE ROAD FROM WHAT MOMENTUM WAS LEFT IN THE CAR, AND AVOID AN ACCIDENT. WE WERE OBVIOUSLY VERY SHAKEN UP, AND FIND THIS CAR COMPLETELY UNSAFE. IT HAS BEEN 3 WEEKS NOW GETTING THE RUN AROUND WITH THE CHERRY HILL, NEW JERSEY VOLVO DEALER. THEY SAID "THERE'S NOTHING WRONG WITH THE CAR". THE CAR IS UNSAFE FOR OUR FAMILY, AND PRESENTS A DANGER FOR OTHERS ON THE ROAD. WE ARE AFRAID IT WILL STOP DEAD AGAIN ON A MAJOR HIGHWAY WITH DEATH OR INJURIES OCCURING TO EITHER OURSELVES OR OTHERS. THE DEALER ASKED US WHAT WE WANTED "WE FINALLY SAID, (AFTER THEY SAID THEY'D GET US A NEW SUV AND DID NOT) THAT WE WANT OUR MONEY BACK ($3,000 DEPOSIT) AND WE DON'T WANT THIS CAR THEY SOLD US. TODAY, THEY MADE US TAKE THIS CAR BACK AND THEY ARE REFUSING OUR REQUEST TO REFUND OUR MONEY. ALSO, THE CAR WAS TOWED ON A FLAT BED TRUCK IN TO THE DEALER ON JULY 13TH, 2004 AS THE CAR DID NOT START.. "RELAYS WERE LOOSE IN THE ICM AND CEM ETC.," [WE HAVE THE SERVICE ORDER] ON THIS DAY, THE MESSAGE ON THE CAR SAID SOMETHING TO THE EFFECT "URGENT MALFUNCTION IN SUV AIR BAGS..." AND WE UNLOADED THE FAMILY AND IT WAS TOWED TO THE VOLVO DEALERSHIP. AND THE CAR'S 2 SIDE MIRRORS WORK ONE DAY AND NOT THE NEXT. TOMORROW I TAKE MATTHEW TO HIS FIRST DAY AT PRE-SCHOOL, AND I'M HALF THINKING WHAT IF SOMETHING HAPPENS TO THE CAR WHEN WE'RE DRIVING. IT'S AMAZING TO ME THAT VOLVO CAN LET ME LEAVE THEIR PARKING LOT WITH THIS CAR THIS EVENING, AND THE AREN'T TAKING SAFETY SERIOUSLY AT ALL. SO, AT 11:00 PM I AM UP LETTING THE NHTSA KNOW WHAT'S GOING ON. WE ARE WILLING TO HELP IN ANYWAY WE CAN. SINCERELY, THE LAWRENCE FAMILY.*AK

NHTSA ODI #10090937

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.