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

70,000 miles · Dec 18, 2008

Power Train

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I HAVE A FIVE YEAR OLD 2004 VOLVO XC90 T6 THAT HAS HAD TWO TRANSMISSION FAILURES. IT IS CURRENTLY AT THE DEALER AWAITING A THIRD TRANSMISSION. THE FIRST TRANSMISSION FAILURE WAS IN AUGUST 2007, THE SECOND WAS IN DECEMBER 2008. I WAS TOLD BY THE DEALER THAT THE FIRST TRANSMISSION FAILED DUE TO "EXCESS METAL" AND THAT THE METAL SOMEHOW TRAVELED TO THE COOLING SYSTEM AND THEN TO THE SECOND TRANSMISSION, WHICH CAUSED IT TO FAIL. THIS IS A DANGEROUS ISSUE AND I FEAR THAT THE CAR IS NEITHER SAFE NOR RELIABLE AT THIS POINT. I PAID $1900 FOR THE FIRST TRANSMISSION TO BE REPLACED. ONE WEEK LATER, I RETURNED TO THE DEALER AND COMPLAINED THAT THE TRANSMISSION WAS HESITATING AND WAS NOT SHIFTING SMOOTHLY. THEY COULD FIND NOTHING. I RETURNED FOUR ADDITIONAL TIMES OVER THE NEXT YEAR WITH THE SAME COMPLAINTS AND THE DEALERSHIP COULD NEVER FIND ANYTHING WRONG. NOW I AM WAITING TO FIND OUT IF VOLVO WILL EVEN OFFER TO PAY FOR THIS THIRD TRANSMISSION. *TR

NHTSA ODI #10252240

80,000 miles · Dec 11, 2008

Power Train

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I HAVE HAD 3 COMPLETE TRANSMISSION FAILURES IN A VOLVO XC90 T6 WITHOUT WARNING REQUIRING REPLACEMENT OF THE TRANSMISSION. THE FIRST TWO FAILED ON THE HIGHWAY ALMOST CAUSING AN ACCIDENT AS THE TRANSMISSION CUT OUT COMPLETELY. THE LAST ONCE OCCURRED ON A BUSY 2 LANE HIGHWAY WHILE MAKING A TURN ACROSS TRAFFIC. THE FIRST ONE FAILED AT 28,000 MILES, THE SECOND AT 55,000 MILES AND THE THIRD AT 80,000 MILES. THE FIRST ONE WAS REPLACED UNDER WARRANTY WITHOUT AN ARGUMENT, THE 2ND ONE WAS REPLACED UNDER WARRANTY WITH AN ARGUMENT, AND THE THIRD ONE VOLVO WON'T EVEN TALK ABOUT REPLACING FOR FREE AND WANTS TO CHARGE OVER 5K, WITHOUT GIVING ANY ASSURANCES ANOTHER 25K WON'T GO BY AND IT WON'T FAIL AGAIN. THEY DON'T CARE THAT THE "SAFEST" CAR CAN INSTANTLY BECOME A DEATH TRAP. A TRANSMISSION ISN'T A DISPOSABLE ITEM THAT SHOULD FAIL EVERY 25K, THEY SHOULD LAST AT LEAST 100K AND NOT CUT OUT IN THESE DANGEROUS FASHIONS WITHOUT WARNING. THE THIRD ONE THERE WEREN'T EVEN ANY WARNING LIGHTS. THE COMPANY SHOULD FIX THIS DANGEROUS PROBLEM AT NO COST TO THE OWNERS WITH A SOLUTION THAT GIVES THE TRANSMISSION A LIFE SIMILAR TO OTHER VEHICLES IN IT'S CLASS. THERE ANSWER IS TO PUT ANOTHER ONE IN, KNOWING IT WILL FAIL AND MAYBE KILL YOU. *TR

NHTSA ODI #10251543

67,000 miles · Nov 25, 2008

Suspension

TL*THE CONTACT OWNS A 2004 VOLVO XC90. WHILE DRIVING APPROXIMATELY 20 MPH, THE PASSENGER SIDE TIRE DETACHED FROM THE AXLE. THE VEHICLE WAS TOWED TO A DEALER AND THEY STATED THAT THE AXLE AND BALL JOINT FAILED. A POLICE REPORT WAS FILED. THE CURRENT AND FAILURE MILEAGES WERE 67,000.

NHTSA ODI #10249823

68,000 miles · Nov 21, 2008

Electrical System

WHILE DRIVING NORTHBOUND ON INTERSTATE 405, MY WIFE HEARD A LOUD "THUMP" FROM THE ENGINE COMPARTMENT. IMMEDIATELY AFTER THIS NOISE, THE ELECTRICAL SYSTEM COMPLETELY SHUT DOWN, AND ALL THE DASH LIGHTS AND ASSOCIATED ELECTRONICS SHUT DOWN. *T

NHTSA ODI #10249532

55,000 miles · Nov 17, 2008

Power Train

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2004 VOLVO XC90 T6 AWD TRANSMISSION FAILURE AT 55,000 MILES - WHEN PURCHASED FROM CARMAX BOTH VOLVO DEALERSHIP (WHO FIXED AN ALTERNATOR PROBLEM CARMAX COULDN'T) AND PRIVATE MECHANIC STATED "THIS VEHICLE HAS BEEN METICULOUSLY MAINTAINED" AND "IT IS STILL A BABY" - ALL SERVICE DONE AS RECOMMENDED. NO SUITABLE REPLACEMENT TRANSMISSION, SEEMS RIDICULOUS TO REPLACE WITH ANOTHER TRANSMISSION TO FAIL AS MOST REPORTED HERE HAVE. VOLVO OFFERS NO COMPENSATION WHATSOEVER, FROM DEALER TO VOLVO OF NA. *TR

NHTSA ODI #10249039

32,014 miles · Nov 17, 2008

Equipment

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ON 10/21/2008 I WAS DRIVING MY 2004 VOLVO XC90 ON THE HIGHWAY RT.93. IT WAS RAINING AND THE INTERIOR OF THE CAR WAS FOGGY. I COULD NOT SEE OUTSIDE SO I TURNED ON THE A/C BUT IT WAS NOT FUNCTIONING. ALSO, THE CD PLAYER WAS NOT WORKED. I BOUGHT MY CAR NEW IN 2004 WITH HAS ONLY 32,014 MILES ON THE CAR NOW. THE BOSTON VOLVO VILLAGE DEALER INSPECTED THE CAR AND SAID THE BLOWER MOTOR, RESISTOR AND THE CD PLAYER NEED TO BE REPLACED. THE COST OF PARTS AND LABOR OF THE BLOWER AND RESISTOR WAS $1,650 AND THE CD $700. I CONTACTED THE VOLVO HEAD OFFICE AND THEY WERE WILLING TO PROVIDE THE PARTS FREE BUT THE LABOR COST ON ME. I HAVE NO CHOICE TO DO IT RIGHT AWAY BECAUSE I HAVE TWO CHILDREN. I NEED THE CAR TO CARRY THEM TO SCHOOL EVERYDAY. IT IS A SAFETY ISSUE IF THE VENTILATION AND HEAT IS NOT WORKING. I CANNOT DRIVE THE CAR IF THERE IS NO VENTILATION AND THE CAR IS FOGGY DURING RAINY OR SNOWY DAYS. IF I WAS IN THE HIGHWAY, I HAVE TO PARK ON THE SIDE FOR THE POOR VISIBILITY. IT WOULD PUT ME AND MY FAMILY IN A DANGEROUS SITUATION. I PAID $1,058 FOR THE LABOR AND $57.50 FOR THE INSPECTION COST. IF THE VOLVO ADMITTED THE PARTS HAS PROBLEM AND WILLING TO REPLACE THEM FREE, THEY SHOULD NOT CHARGE ME LABOR COST. *TR

NHTSA ODI #10248977

49,500 miles · Nov 6, 2008

Power Train

MY 2004 VOLVO XC90 TRANSMISSION HAD TO REPLACED AND THEY HAD TO TOW THE CAR TWICE BECAUSE THE FIRST TIME THEY TOLD ME THE PROBLEM WAS FIXED . MY LITTLE CHILDREN WERE IN THE CAR THAT JUST ABOUT MADE IT HOME. *TR

NHTSA ODI #10247849

67,000 miles · Oct 28, 2008

Power Train

MY 2004 VOLVO XC90 T6 TRANSMISSION HAS FAILED. I BOUGHT THE VEHICLE IN JANUARY 2007, WITH NO EXTENDED WARRANTY. I HAVE ABOUT 67K MILES ON IT AND BOUGHT IT WITH 38K. THE DEALERSHIP IS CHARGING ME $4,200 TO REPLACE IT. I HAVE BEEN READING MANY COMPLAINTS FROM PEOPLE HAVING THE SAME COMPLAINT. I FEEL THAT THIS TRANSMISSION IS …

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NHTSA ODI #10246908

68,000 miles · Oct 27, 2008

Power Train

WHILE DRIVING MY 2004 VOLVO XC-90, THE TRANSMISSION WENT OUT ON THE HIGHWAY AND THE VEHICLE WOULD NOT ACCELERATE. THERE WAS NOT WARNING, AND WE ALMOST GOT INTO A CAR ACCIDENT WITH A TRUCK. MY WIFE IS 8 MONTHS PREGNANT, AND WE WERE VERY SCARED. *TR

NHTSA ODI #10246804

33,193 miles · Oct 24, 2008

Electrical System

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ON OCTOBER 18 AT APPROXIMATELY 8PM WE WERE TRAVELING WEST BOUND ON I-4 WHEN WE EXPERIENCED A SEVERE "JERK" OF THE VEHICLE AND THE INTERIOR SEATBELTS LIGHTS LIT UP. WE CONTINUED TO DRIVE AND EXPERIENCED THE SAME THING A FEW MILES LATER. WE DECIDED TO EXIT AND THEN THERE WAS ANOTHER "JERK" OF THE VEHICLE AND WE LOST ALL INTERIOR ELECTRICAL, NO DASH LIGHTS, NO A/C, NO WINDOWS, NOTHING! WE LIMPED TO A PARKING LOT AND CALLED ROAD SIDE ASSISTANCE TO HAVE THE VEHICLE TOWED. THIS IS A SERIOUS ISSUE WITH THIS VEHICLE AND I HAVE FOUND MULTIPLE INSTANCES OF THE SAME ON YOUR WEBSITE! VOLVO NEEDS TO RECALL THE VEHICLE AND MAKE THE REPAIRS BEFORE SOMEONE IS KILLED! VOLVO CAN'T SEEM TO REPLICATE THE PROBLEM AND THE COMPUTER IN THE CAR DID NOT REGISTER AN EVENT! SEEMS LIKE THE COMPUTER IS THE PROBLEM, BUT THEY WON'T "OWN" UP TO THE FACT THAT IT'S A VOLVO PROBLEM! *TR

NHTSA ODI #10246605

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.