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

Suspension complaints

23 reports

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84,000 miles · Feb 3, 2008

Suspension

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REAR HUB (BEARINGS) ON PASSENGER SIDE FAILED. THIS IS THE THIRD TIME A REAR HUB FAILED. THE FIRST TIME IN 2005 THE VEHICLE HAD 28,000 MILES. THIS TIME THE REAR WHEEL WAS HELD ON BY THE BRAKE CALIPER ACCORDING TO THE VOLVO DEALER THAT REBUILT IT. THE SECOND WAS THE DRIVER SIDE REAR HUB FAILED IN 2007 WITH 72,000 MILES. THE THIRD WAS THE PASSENGER SIDE REAR HUB THAT FAILED ABOUT A WEEK AGO. THE VEHICLE MILEAGE WAS 84,000. THIS VEHICLE IS MAINTAINED ACCORDING TO THE MANUFACTURER'S SCHEDULE. IT IS QUITE DANGEROUS (REFER TO THE FIRST INCIDENT). THERE NEEDS TO BE A RECALL WOULD SEEM TO BE THE CORRECT OUTCOME. THOUGH THERE IS AN EXTENDED WARRANTY AFTER THE 50,000 MILE PERIOD THERE HAS BEEN A COST TO US. *TR

NHTSA ODI #10216808

56,015 miles · Oct 17, 2007

Suspension

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I HAVE NOW EXPERIENCED THE FAILURE OF THE SECOND REAR WHEEL BEARING ON MY 2004 VOLVO XC-90 AWD, WITH THE SECOND FAILURE RESULTING IN THE PARTIAL SEPARATION OF THE WHEEL FROM THE VEHICLE AT HIGHWAY SPEEDS. THERE IS A DEFECT IN THE DESIGN OF THE WHEEL BEARING, AND THESE BEARINGS SHOULD BE REPLACED IN THE FIELD BEFORE THER IS A FATALITY OR SERIOUS INJURY. ALTHOUGH VOLVO HAS REPLACED BOTH BEARINGS UNDER WARRANTY, A BRIEF INTERNET SEARCH INDICATES THIS IS A VERY COMMON FAILURE ON THIS MODEL. DAMAGE ON THE SECOND FAILURE RESULTED IN $1800 DAMAGE TO THE VEHICLE. *JB

NHTSA ODI #10206023

9,750 miles · Oct 9, 2007

Electrical SystemExterior LightingSeat Belts

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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

34,500 miles · Jul 14, 2007

Power TrainSuspension

I HAVE MY 2004 XC90 T6. AT ABOUT 34K MILES A NOTICEABLE 'THRUM' BEGAN SOMEWHERE IN THE DRIVETRAIN. ORIGINAL DIAGNOSIS WAS WORN TIRES. AFTER REPLACING TIRES, THE NOISE HAS BECOME WORSE. NOW AT 35K MILES IS VERY LOUD. NEW DIAGNOSIS IS FAILING WHEEL BEARING. A BIT OF RESEARCH INDICATES I AM NOT THE ONLY XC90 OWNER WITH A WHEE…

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NHTSA ODI #10196357

40,000 miles · Jun 22, 2007

Suspension

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WHEEL BEARING FAILURE. VOLVO XC90 PUT AN SUV ONTOP OF A CAR CHASSIS CAUSING TOO MUCH LOAD ON WHEELS AND WHEEL BEARING. TIRES WEAR OUT OFTEN AND BEARINGS NEED TO BE REPLACED REPEATEDLY. IF YOU SEARCH FORUMS LIKE:HTTP://TOWNHALLTALK.EDMUNDS.COM/DIRECT/VIEW/.F0ED3F5/0 HTTP://FORUMS.SWEDESPEED.COM/ZEROTHREAD?ID=77305 HTTP://WWW.VOLVO-FORUMS.COM/T7392-RELIABILITY-CONCERNS-ABOUT-2006-XC90.HTM YOU WILL SEE THAT MANY CAR OWNERS HAVE THIS SAME PROBLEMS. VOLVO NEED TO LET CUSTOMERS KNOW THAT THIS IS A PROBLEM. THIS IS DANGEROUS AND CAN CAUSE SERIOUS INJURY. INSTEAD OF KEEPING IT HUSH THEY SHOULD INFORM CONSUMERS AND DO A RECALL. *TR

NHTSA ODI #10193995

70,000 miles · Jun 15, 2007

Suspension

TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT HEARD A NOISE WHILE DRIVING 25-30 MPH. THERE WERE NO WARNING INDICATORS. THE REAR BEARING AXLE WAS REPLACED. THE TUMBLER IGNITION LOCK FAILED AND THE KEY COULD NOT BE REMOVED. THE VEHICLE WAS TOWED AND THE IGNITION LOCK WAS REPLACED. THE VIN, PURCHASE DATE, AND ENGINE SIZE…

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NHTSA ODI #10193463

55,400 miles · Apr 24, 2007

SuspensionWheels

WHEEL BEARINGS HAVE BEEN REPLACED TWICE UNDER WARRANTY. THE PROBLEM HAS RECURRED. THIS PART NEEDS TO BE RECALLED. *JB

NHTSA ODI #10188745

40,000 miles · Sep 19, 2006

Suspension

I HAVE A 2004 VOLVO XC90 WITH ROUGHLY 40,000 MILES. I JUST HAD THE REAR WHEEL BEARING REPLACED FOR THE SECOND TIME. THE FIRST TIME WAS AT ROUGHLY 10,000 MILES. I AM VERY CONCERNED THAT THEY HAVE FAILED TWICE. I UNDERSTAND THAT IF THE CONDITION OF THE BEARINGS IS BAD ENOUGH, THE WHEEL CAN FALL OFF. I FEEL VOLVO SHOULD EXTEND…

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NHTSA ODI #10168668

58,439 miles · Aug 17, 2006

Suspension

DT*: THE CONTACT STATED THERE WAS A CONTINUOUS HUMMING NOISE THAT BECAME LOUDER AS THE VEHICLE SPEED INCREASED; THE HUMMING WAS PRESENT AT ALL SPEEDS. THE DEALERS SERVICE MECHANIC DETERMINED THE PROBLEM WAS THE HUB AND BEARING ASSEMBLY IN THE LEFT REAR WHEEL. THE PART WAS REPLACED AND THE MANUFACTURER WAS NOTIFIED. *AK UPDATED …

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NHTSA ODI #10165775

28,398 miles · Jun 13, 2006

SteeringSuspension

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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

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.