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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

What owners actually said

462 reports
97,000 miles · Mar 24, 2010
Electrical System

TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED WHILE DRIVING AT SPEEDS OF 50 MPH THE VEHICLE WOULD STALL AND THE ELECTRICAL SYSTEM WOULD MALFUNCTION. THIS WOULD CAUSE THE POWER WINDOWS AND INTERIOR LIGHTS TO BECOME INOPERABLE. THE DEALER COULD NOT DUPLICATE THE FAILURES. THE CONTACT STATED THAT HE WAS ABLE TO LOCATE …

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TL*THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED WHILE DRIVING AT SPEEDS OF 50 MPH THE VEHICLE WOULD STALL AND THE ELECTRICAL SYSTEM WOULD MALFUNCTION. THIS WOULD CAUSE THE POWER WINDOWS AND INTERIOR LIGHTS TO BECOME INOPERABLE. THE DEALER COULD NOT DUPLICATE THE FAILURES. THE CONTACT STATED THAT HE WAS ABLE TO LOCATE SEVERAL COMPLAINTS PERTAINING TO THE FAILURE AND DID NOT FEEL SAFE IN THE VEHICLE. HE ALSO STATED THAT THE FAILURE CONTRIBUTED TO A DEFECTIVE COMPUTER AND SHOULD BE THE MANUFACTURERS LIABILITY. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 97,000.

NHTSA ODI #10321856

104,000 miles · Mar 23, 2010
Power Train

PURCHASED A 2004 VOLVO T6 XC90 USED WITH 98,000 MILES. AT 104000 THE TRASNMISSION FAILED. THEY NEED $6500 TO REPAIR IT. IF IT HAD GONE AT 99,999 THEY WOULD PAY FOR THE REPAIR AS IT IS A KNOWN ISSUE AND ARE PAYING FOR 100% IF UNDER 100,000. HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F18A651/470 FOR ADDTIONAL TESTIMONY. THANK Y…

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PURCHASED A 2004 VOLVO T6 XC90 USED WITH 98,000 MILES. AT 104000 THE TRASNMISSION FAILED. THEY NEED $6500 TO REPAIR IT. IF IT HAD GONE AT 99,999 THEY WOULD PAY FOR THE REPAIR AS IT IS A KNOWN ISSUE AND ARE PAYING FOR 100% IF UNDER 100,000. HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F18A651/470 FOR ADDTIONAL TESTIMONY. THANK YOU

NHTSA ODI #10321528

102,000 miles · Mar 19, 2010
Power Train

TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED WHILE DRIVING 45 MPH THE TRANSMISSION FAILED. HE NOTICED NUMEROUS COMPLAINTS REGARDING THE TRANSMISSION FOR THIS YEAR MAKE AND MODEL, SO THE CONTACT DROVE THE VEHICLE TO THE DEALER. THE DEALER DIAGNOSED THE VEHICLE AND INFORMED THE CONTACT THAT THE TRANSMISSION COOLAN…

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TL* THE CONTACT OWNS A 2004 VOLVO XC90. THE CONTACT STATED WHILE DRIVING 45 MPH THE TRANSMISSION FAILED. HE NOTICED NUMEROUS COMPLAINTS REGARDING THE TRANSMISSION FOR THIS YEAR MAKE AND MODEL, SO THE CONTACT DROVE THE VEHICLE TO THE DEALER. THE DEALER DIAGNOSED THE VEHICLE AND INFORMED THE CONTACT THAT THE TRANSMISSION COOLANT LINE NEEDS TO BE REPLACED. THE CONTACT ASKED THE SERVICE MANAGER IF THE MANUFACTURER WAS WILLING TO PAY FOR HALF OF THE COST OF THE REPAIRS AND THE MANUFACTURER DECLINED. THE CONTACT FEELS A RECALL SHOULD BE ISSUE BECAUSE OF THE NUMEROUS COMPLAINTS REGARDING THIS YEAR MAKE AND MODEL FOR THE TRANSMISSION PROBLEM. THE FAILURE MILEAGE WAS 102,000.

NHTSA ODI #10321005

42,000 miles · Mar 18, 2010
Power Train

IN AUGUST OF 2009 I BEGAN NOTICING THAT MY VOLVO XC90 T6 WAS SLOW TO SWITCH GEARS OR WOULD CHUG BEFORE SWITCHING. IT WOULD NOT HAPPEN ALL OF THE TIME AND WHEN I MENTIONED IT TO MY HUSBAND HE SAID HE HAD NOT NOTICED IT. I FIGURED IT WAS NO BIG DEAL OR THAT IT WAS RELATED TO A COLD ENGINE. DURING THE MIDDLE OF OCTOBER 2009, I…

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IN AUGUST OF 2009 I BEGAN NOTICING THAT MY VOLVO XC90 T6 WAS SLOW TO SWITCH GEARS OR WOULD CHUG BEFORE SWITCHING. IT WOULD NOT HAPPEN ALL OF THE TIME AND WHEN I MENTIONED IT TO MY HUSBAND HE SAID HE HAD NOT NOTICED IT. I FIGURED IT WAS NO BIG DEAL OR THAT IT WAS RELATED TO A COLD ENGINE. DURING THE MIDDLE OF OCTOBER 2009, I WAS COMING HOME FROM WORK AND MERGING ONTO A TWO LANE BRIDGE WHEN MY VOLVO REFUSED TO SWITCH GEARS AND WOULD NOT GO OVER 20 MILES PER HOUR. THE TRANSMISSION LIGHT WENT ON. THANKFULLY NO OTHER CARS WERE AROUND AND MY LACK OF SPEED DID NOT CAUSE AN ACCIDENT. AFTER ABOUT 10 MINUTES I WAS ABLE TO SPEED UP AND MADE IT BACK HOME. THE CAR IS IN NEED OF A NEW TRANSMISSION. IT HAS SAT IN MY DRIVEWAY FOR 5 MONTHS BECAUSE I CAN NOT AFFORD IT. I'VE GOTTEN ONLINE ONLY TO FIND OUT THAT I AM NOW A MEMBER OF A RAPIDLY GROWING CLUB OF FRUSTRATED VOLVO OWNERS. IT FRUSTRATES ME THAT THIS IS A COMMON PROBLEM WITH THIS YEAR/MAKE OF VOLVO'S. MY CAR HAS 40,000 MILES ON IT. THE TRANSMISSION PROBLEM IN THESE CARS NEEDS TO BE FORMALLY ADDRESSED. IT IS A HUGE SAFETY HAZARD WHEN A CAR ALL OF A SUDDEN JERKS AROUND AND WON'T ACCELERATE TO SAFELY MERGE INTO FAST MOVING TRAFFIC. *TR

NHTSA ODI #10320607

89,000 miles · Mar 8, 2010
Power Train

2004 XC90 HAS A HUGE PROBLEM WITH TRANSMISSION PROBLEMS. FOR A BRAND NEW 2004 XC 90, EVERY TWO YEARS EXPECT TO CHANGE THE TRANSMISSION. OTHERWISE YOU WILL STUCK IN THE FREEWAY ESPECIALLY YOU ARE PLANNING TO TRAVEL, DO NOT USE THAT CAR IF IT'S CLOSE TO TWO YEARS. *TR

NHTSA ODI #10317614

46,000 miles · Mar 1, 2010
Air BagsElectrical SystemElectronic Stability Control (esc)

MY 2004 VOLVO XC90 HAS EXPERIENCE A SUDDEN ELECTRICAL FAILURE. WHILE DRIVING IN CITY CONDITIONS ALL INTERNAL ELECTRONICS INCLUDING SPEED & FUEL GAUGES, TURN LIGHT INDICATORS, AUDIO SYSTEM, AIR CIRCULATION AND SUPPLEMENTAL RESTRAINT SYSTEM HAVE TURNED OFF WHILE THE ENGINE CONTINUED TO OPERATE. THIS MADE THE CAR IMPOSSIBLE TO DR…

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MY 2004 VOLVO XC90 HAS EXPERIENCE A SUDDEN ELECTRICAL FAILURE. WHILE DRIVING IN CITY CONDITIONS ALL INTERNAL ELECTRONICS INCLUDING SPEED & FUEL GAUGES, TURN LIGHT INDICATORS, AUDIO SYSTEM, AIR CIRCULATION AND SUPPLEMENTAL RESTRAINT SYSTEM HAVE TURNED OFF WHILE THE ENGINE CONTINUED TO OPERATE. THIS MADE THE CAR IMPOSSIBLE TO DRIVE AS NO FEEDBACK ON SPEED OR ABILITY TO INDICATE A TURN OR A STOP WAS POSSIBLE. THIS OCCURRED SUDDENLY AND WITHOUT ANY WARNING. I WAS UNABLE TO FIX THIS BY RESTARTING THE CAR. ACCORDING TO BASIC RESEARCH, THIS IS A COMMON ISSUE WITH VOLVO CARS MADE CIRCA 2003-4 AND INVOLVE A DEFECTIVE CEM (CAR ELECTRONICS MODULE). IN OTHER INCIDENTS ENGINES HAVE ALSO SHUT DOWN UNEXPECTEDLY AND BRAKES BECAME INOPERABLE. THIS IS A SERIOUS SAFETY ISSUE THAT NEEDS TO BE ADDRESSED. *TR

NHTSA ODI #10315285

Mileage unknown · Mar 1, 2010
Fuel System, Gasoline

RECALL 2004 VOLVO XC90 FUEL PUMP *BF THE CONSUMER STATED SHE EXPERIENCED THE PROBLEM BACK IN OCTOBER 2008. THERE WAS A HORRIBLE GAS SMELL COMING FROM THE VEHICLE. THE DEALER WAS UNABLE TO DIAGNOSE THE PROBLEM THE FIRST TIME. THE CONSUMER IS SEEKING REIMBURSEMENT. *JB

NHTSA ODI #10313205

122,450 miles · Feb 17, 2010
Power Train

FAILURE OF THE VOLVO-MODIFIED GM 4T65EV/GT TRANSMISSION IN 2003-2005 VOLVO XC90 T6 SUV. KNOWN TO VOLVO WORLDWIDE (AND WELL DOCUMENTED IN MANY INTERNET CHAT FORUMS) IS A DESIGN FLAW IN THE VOLVO MODIFICATION OF THE VALVE BODY IN THE GM 4T65EV/GT TRANSMISSION CAUSING SUDDEN AND OFTEN CATASTROPHIC FAILURE OF THE TRANSMISSION. THE…

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FAILURE OF THE VOLVO-MODIFIED GM 4T65EV/GT TRANSMISSION IN 2003-2005 VOLVO XC90 T6 SUV. KNOWN TO VOLVO WORLDWIDE (AND WELL DOCUMENTED IN MANY INTERNET CHAT FORUMS) IS A DESIGN FLAW IN THE VOLVO MODIFICATION OF THE VALVE BODY IN THE GM 4T65EV/GT TRANSMISSION CAUSING SUDDEN AND OFTEN CATASTROPHIC FAILURE OF THE TRANSMISSION. THE TRANSMISSION MAY GO INTO "LIMP HOME" MODE LEAVING ONLY 3RD GEAR AVAILABLE, OR MAY SEIZE COMPLETELY. MANY OWNERS HAVE REPORTED SUDDEN INABILITY TO ACCELERATE FROM A STOP CREATING TRAFFIC COLLISION HAZARD. MANY OWNERS REPORT PRESSING ACCELERATOR WITH NO FORWARD MOTION, ONLY INCREASING ENGINE RPM, THEN SUDDEN ENGAGEMENT OF TRANSMISSION CAUSING LURCHING AND POTENTIAL LOSS OF CONTROL. I PERSONALLY OWN A 2004 VOLVO XC90 T6 SUV WITH THIS TRANSMISSION. THE VEHICLE NOW HAS OVER 122,500 MILES. IT HAD ITS FIRST TRANSMISSION REPLACEMENT AT 72K MILES AT A COST OF OVER $4700 USD TO ME. NOW, 50K LATER AT 122K, THE TRANSMISSION HAS FAILED AGAIN. VOLVO CARS OF NORTH AMERICA HAS DENIED REQUESTS FOR REIMBURSEMENT OF MY INITIAL TRANSMISSION REPLACEMENT. THEY OFFERED 50% ON PARTS AND LABOR "WHEN THE NEXT TRANSMISSION IS NEEDED". THIS OCCURRED LAST WEEK; MY DEALERSHIP ASKED VOLVO CARS OF NORTH AMERICA TO RECONSIDER PAYING THE FULL AMOUNT AND THEY DID. I WANT THE FIRST REPLACEMENT TRANSMISSION COST REIMBURSED TO ME AND EVERY OTHER OWNER THAT HAS HAD TO PAY FOR AN ENGINEERING PROBLEM THAT VOLVO HAS ADMITTED TO. I ALSO SEEK A DEFINITIVE REPAIR SO I MAY UTILIZE THIS VEHICLE FOR WHAT IT WAS DESIGNED FOR; TOWING, LIGHT OFF-ROADING, CARRYING MY 6 DAUGHTERS AND WIFE SAFELY. *TR

NHTSA ODI #10311511

54,000 miles · Feb 1, 2010
Engine And Engine CoolingFuel System, DieselPower Train

TRANSMISSION FAILURE TWICE AND FUEL PUMP REPLACED AND STILL LEAKING IN OUR VOLVO XC90 2004 T6 TRUCK. VOLVO REPLACED THE TRANSMISSION TWICE, BUT WE STILL HAD REPAIR COSTS BOTH TIMES. FUEL PUMP REPLACED AND STILL LEAKING CAUSING LARGE AMOUNTS OF GAS FUMES IN VEHICLE. TAKING INTO VOLVO TO FIX FUEL PUMP AGAIN TODAY THAT IS COVERED U…

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TRANSMISSION FAILURE TWICE AND FUEL PUMP REPLACED AND STILL LEAKING IN OUR VOLVO XC90 2004 T6 TRUCK. VOLVO REPLACED THE TRANSMISSION TWICE, BUT WE STILL HAD REPAIR COSTS BOTH TIMES. FUEL PUMP REPLACED AND STILL LEAKING CAUSING LARGE AMOUNTS OF GAS FUMES IN VEHICLE. TAKING INTO VOLVO TO FIX FUEL PUMP AGAIN TODAY THAT IS COVERED UNDER THE RECALL BUT JUST GOT IT BACK FROM 2ND TRANSMISSION REPAIR WHERE I HAD TO PAY FOR THE INTERNAL ENGINE LEAKS THAT COULD NOT BE DETECTED THAT IN TURN CONTAMINATED THE 2ND TRANSMISSION. I DO NOT BELIEVE I SHOULD HAVE PAID $1600 IN REPAIRS WHEN IT HAS BEEN SERVICED AND CANNOT DETECT THESE INTERNAL OIL LEAKS FROM THE ENGINE. THIS MAKE AND MODEL YEAR HAS BEEN COSTLY AND DANGEROUS. TRUCK HAS STOPPED IN THE MIDDLE OF LEFT TURN, ALMOST RESULTING IN HEAD ON COLLISION. THIS TRUCK SEEMS TO FALL UNDER LEMON LAW. WE HAVE HAD PROBLEMS WITH THIS TRUCK SINCE 2007.IT HAS HAD 2 TRANSMISSION REPLACEMENTS AND NOW 2 FUEL PUMPS,BOTH VOLVO PUMPS. I SHOULD INCUR ZERO COSTS OTHER THAN OIL CHANGES AND GENERAL MAINTENANCE. THESE ARE MAJOR EQUIPMENT FAILURES IN THIS VOLVO XC90 T6 2004 AND THE ENTIRE VEHICLE SHOULD BE RECALLED. I WILL BE SUBMITTING MY REPAIR COSTS TO VOLVO NORTH AMERICA. THANK YOU FOR YOUR REVIEW OF THIS IN ADVANCE. *TR

NHTSA ODI #10303556

126,000 miles · Jan 31, 2010
Power Train

ON THE WAY BRINGING OUR DAUGHTER HOME FROM HOSPITAL, THIRD GEAR WENT OUT OF THE TRANSMISSION. AFTER SAVING ENOUGH MONEY TO REPLACE THE TRANSMISSION, NOT FIVE THOUSAND MILES LATER THE REVERSE GOES OUT OF THE TRANSMISSION THAT WE REPLACED, LEAVING MY SIX MONTH OLD DAUGHTER AND I STRANDED. THE VEHICLE IS NOW SITTING AT THE TRANSMIS…

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ON THE WAY BRINGING OUR DAUGHTER HOME FROM HOSPITAL, THIRD GEAR WENT OUT OF THE TRANSMISSION. AFTER SAVING ENOUGH MONEY TO REPLACE THE TRANSMISSION, NOT FIVE THOUSAND MILES LATER THE REVERSE GOES OUT OF THE TRANSMISSION THAT WE REPLACED, LEAVING MY SIX MONTH OLD DAUGHTER AND I STRANDED. THE VEHICLE IS NOW SITTING AT THE TRANSMISSION SHOP, AND HAS BEEN FOR SEVEN MONTHS, WAITING TO GET FIXED. HOWEVER, I AM NOW A SINGLE MOTHER TRYING TO GO TO SCHOOL AND LIVE OFF OF FINANCIAL AID, SO WHAT I AM SAYING; THERE IS OBVIOUSLY SOMETHING WRONG WITH THESE TRANSMISSIONS. PLEASE INVESTIGATE FURTHER. *TR

NHTSA ODI #10303409

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.