Illustration2005 VOLVO XC 90 T6 TRANSMISSION FAILURE AND TURN SIGNAL NOT OPERATING. *TR
2005 Volvo XC90
Owner reports · Recalls · Investigations
More warning signs than most XC90 years
Owner complaints for the 2005 Volvo XC90 are substantially higher than the model-year median of 34.
About this comparison →How this year compares
Owner complaints by model year
Compare all XC90 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
140–25K
1325–50K
5350–75K
4375–100K
56100–150K
16150K+
195 reports with mileage · 28 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.
- Power Train. Review the 62 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 51 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. 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.
1 crash reports3 fire reports1 injury reports
What owners actually said
223 reportsI HAVE A 2005 VOLVO XC90 AWD. MY HEAD LIGHTS HAVE INTERMITTENT FAILURES ALMOST EVERY TIME I AM DRIVING AT NIGHT. IT STARTED ABOUT 10 MONTHS AGO AND HAS BEEN GETTING MORE FREQUENT. SOMETIMES LEFT HEAD LIGHT FAILS, SOMETIMES RIGHT HEAD LIGHT FAILS, SOMETIMES BOTH GO OUT. THEY WILL RESUME WORKING, SOMETIMES IF I DO NOTHING, BUT ALW…
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I HAVE A 2005 VOLVO XC90 AWD. MY HEAD LIGHTS HAVE INTERMITTENT FAILURES ALMOST EVERY TIME I AM DRIVING AT NIGHT. IT STARTED ABOUT 10 MONTHS AGO AND HAS BEEN GETTING MORE FREQUENT. SOMETIMES LEFT HEAD LIGHT FAILS, SOMETIMES RIGHT HEAD LIGHT FAILS, SOMETIMES BOTH GO OUT. THEY WILL RESUME WORKING, SOMETIMES IF I DO NOTHING, BUT ALWAYS IF I TURN THEM OFF & BACK ON. BUT WILL CONTINUE TO FAIL. THE DEALER SAID THEY CANNOT FIND ANY PROBLEM. *TR
ME AND MY WIFE JUST BOUGHT OUR FIRST VOLVO 4 DAYS AGO!!! AND MY WIFE WAS ON THE HIGH WAY WITH OUR 7 MONTH OLD SON WHEN THE TRANSMISSION FAILED ON HER AND THEY ALMOST GOT INTO A CAR ACCIDENT. THANK GOD SHE WAS ABLE TO PULL OVER ON THE SIDE OF THE HIGH WAY AND CALL AAA AND WE HAD THE CAR TOWED TO THE VOLVO DEALER WERE WE BOUGHT IT…
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ME AND MY WIFE JUST BOUGHT OUR FIRST VOLVO 4 DAYS AGO!!! AND MY WIFE WAS ON THE HIGH WAY WITH OUR 7 MONTH OLD SON WHEN THE TRANSMISSION FAILED ON HER AND THEY ALMOST GOT INTO A CAR ACCIDENT. THANK GOD SHE WAS ABLE TO PULL OVER ON THE SIDE OF THE HIGH WAY AND CALL AAA AND WE HAD THE CAR TOWED TO THE VOLVO DEALER WERE WE BOUGHT IT FROM BECAUSE THEY GAVE US A 3 MONTH/ 3000 MILE WARRANTY. AND NOW IT'S BEEN 3 DAYS AND WE HAVE NO CAR AND THE DEALER IS SAYING THAT THEY ARE TRYING TO REPROGRAM THE TRANSMISSION. I WISH THAT I WOULD HAVE READ SOME OF THESE REVIEWS ON THIS MODEL CAR. BECAUSE THEY ALL SEEM TO HAVE TRANSMISSION PROBLEMS AND THEY SHOULD HAVE RECALLED THAT PROBLEM. WHAT SHOULD WE DO? [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
I OWN A 2005 VOLVO XC 90 MODEL T6 WITH ABOUT 60,000 MILES ON IT. RECENTLY, THE CAR FAILED AND I GOT THE "URGENT TRANSMISSION SERVICE" WARNING. VOLVO INITIALLY WANTED TO CHARGE ME NEARLY $7000 TO REPLACE THE TRANSMISSION BUT FINALLY AGREED TO COVER THE COST (MINUS A $160 "DIAGNOSIS PLUS MY TOWING COSTS). AFTER SOME INTERNET RESEA…
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I OWN A 2005 VOLVO XC 90 MODEL T6 WITH ABOUT 60,000 MILES ON IT. RECENTLY, THE CAR FAILED AND I GOT THE "URGENT TRANSMISSION SERVICE" WARNING. VOLVO INITIALLY WANTED TO CHARGE ME NEARLY $7000 TO REPLACE THE TRANSMISSION BUT FINALLY AGREED TO COVER THE COST (MINUS A $160 "DIAGNOSIS PLUS MY TOWING COSTS). AFTER SOME INTERNET RESEARCH I SAW THAT THIS HAS BEEN A COMMON PROBLEM IN MODEL YEAR 2003-2005 T6 MODELS; ALL CATASTROPHIC TRANSMISSION FAILURES WITH LOW MILEAGE, IN SOME CASES MULTIPLE TRANSMISSIONS INVOLVED. SEE ATTACHED LINK: HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F18A651 TALKING TO THE SERVICE REPRESENTATIVE, THEY CLAIMED IT WAS BECAUSE THEY USED A GM TRANSMISSION THAT WAS NOT ABLE TO HANDLE THE POWER OF THE ENGINE (OR PERHAPS THE WEIGHT OF THE CAR). THEY INSTALLED A "REMANUFACTURED" TRANSMISSION, THEY CLAIM WITH "BEEFED UP" CLUTCH PARTS. THERE HAVE BEEN SERVICE BULLETINS SINCE 2008 ABOUT LEAKS FROM THE RADIATOR CONTAMINATING THE TRANSMISSION FLUID (LEADING TO FAILURES AS WELL). IT IS MY UNDERSTANDING THAT THERE HAVE BEEN HUNDREDS OF THESE FAILURES. THERE IS ALSO A CLASS ACTION LAWSUIT UNDERWAY AS WELL. IN MY CASE, I WAS ON A MAJOR HIGHWAY, AND IT WAS A VERY DANGEROUS SITUATION. I DON'T UNDERSTAND WHY THE GOVERNMENT IS NOT DOING ANYTHING ABOUT THIS, AS I WAS ABLE TO FIND A GREAT DEAL OF INFORMATION AFTER JUST A FEW SIMPLE INTERNET SEARCHES. I WOULD LIKE TO REQUEST AN INVESTIGATION, AND IF WARRANTED, A RECALL AND COMPENSATION (THE USED CAR VALUE FOR THIS CAR HAVE DROPPED BECAUSE OF THE LACK OF RELIABILITY OF THE TRANSMISSIONS). I BELIEVE VOLVO IS TRYING TO DEAL WITH THIS ON A CASE BY CASE BASIS TO COVER IT UP AND MINIMIZE THEIR COSTS. *TR
COUNTERBALANCE SHAFT BEARINGS BREAKDOWN IN NOV 2009 AND HAD REPAIRS DONE AT INDEPENDENT REPAIR SHOP; AUGUST 2010 CYLINDER HEAD LEAK/CRACK WHICH BRINGS OIL TO WATER COOLANT. REPAIR SHOP ADVISED TO GET RID OF CAR 2005 XC 90 V8 VOLVO. I AM FEARFUL OF DRIVING THIS CAR. TO REPAIR AND REPLACE ENGINE AND NEW TRANSMISSION TOO MUCH $…
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COUNTERBALANCE SHAFT BEARINGS BREAKDOWN IN NOV 2009 AND HAD REPAIRS DONE AT INDEPENDENT REPAIR SHOP; AUGUST 2010 CYLINDER HEAD LEAK/CRACK WHICH BRINGS OIL TO WATER COOLANT. REPAIR SHOP ADVISED TO GET RID OF CAR 2005 XC 90 V8 VOLVO. I AM FEARFUL OF DRIVING THIS CAR. TO REPAIR AND REPLACE ENGINE AND NEW TRANSMISSION TOO MUCH $$$ FOR THIS VOLVO. WITH NO GUARANTEE. VOLVO NEEDS TO OWN UP TO THE BAD QUALITY OF THIS PARTICULAR MODEL. I FEEL IT IS DANGEROUS TO DRIVE WITH SO MANY CARS ON THE ROAD. IT'S AN ACCIDENT WAITING TO HAPPEN. *TR
THIS IS A SECOND REPORT I SUBMIT. THE OTHER DAY I JUST REPORTED MALFUNCTION OF TURN SIGNAL SWITCH OF MY VOLVO XC90, 2.5T, 2005. I TESTED AND OBSERVED THE PERFORMANCE OF THE TURN SIGNAL SWITCH CAREFULLY AND I THINK THE POTENTIAL SEVERE DESIGN DEFECT IN THE TURN SIGNAL SWITCH, OR, MAYBE THE ELECTRONIC CONTROL MODULE, WILL CAUSE FA…
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THIS IS A SECOND REPORT I SUBMIT. THE OTHER DAY I JUST REPORTED MALFUNCTION OF TURN SIGNAL SWITCH OF MY VOLVO XC90, 2.5T, 2005. I TESTED AND OBSERVED THE PERFORMANCE OF THE TURN SIGNAL SWITCH CAREFULLY AND I THINK THE POTENTIAL SEVERE DESIGN DEFECT IN THE TURN SIGNAL SWITCH, OR, MAYBE THE ELECTRONIC CONTROL MODULE, WILL CAUSE FATAL INCIDENTS. ITS PERFORMANCE IS TOTALLY UNPREDICTABLE. IT REFUSED TO RESPOND AT ANY TIME, EITHER STOPPED OR RUNNING. MOREOVER, I FOUND THAT SOMETIMES A RIGHT MOVEMENT OF THE LEVER GIVES A LEFT SIGNAL, WHICH IS EXTREMELY DANGEROUS. HERE I WOULD LIKE TO STRONGLY REQUEST THAT THE INVESTIGATION OF VOLVO XC90 ELECTRONIC SYSTEM BE CONDUCTED THOROUGHLY. I WOULD NOT BE SURPRISED AT ALL TO HEAR ANY FATAL INCIDENT CAUSED BY THE UNPREDICTABLE MALFUNCTION. AND I HOPE THIS COULD BE PART OF A RECALL. INTERESTINGLY, I OBSERVED THAT ALL THE FUNCTIONS RELATED TO THE SWITCH LEVER EITHER DISAPPEAR ALTOGETHER OR WORKS WELL ALTOGETHER. THIS PARTIALLY SUPPORT THAT THERE IS DEFECT IN THE CONTROL MODULE. I WOULD LIKE TO HELP THE INVESTIGATION. I ALSO HAVE TWO WITNESSES WHO HELPED ME TO TEST DRIVE MY XC90. *TR
I BOUGHT A USED VOLVO XC90, 2.5T MODEL, MANUFACTURED IN 2005. AND YESTERDAY I DROVE IT FOR ABOUT 30 MILES. VOLVO IS FAMOUS FOR VARIOUS SAFETY FEATURES. HOWEVER, I FOUND THAT FOR MANY TIMES THE TURN SIGNAL LEVER DID NOT WORK WELL, WHICH REALLY SCARED ME AND ALMOST CAUSED CRASHES ON HIGHWAY 610 OF HOUSTON. THE SYMPTOM OF MALFUNCTI…
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I BOUGHT A USED VOLVO XC90, 2.5T MODEL, MANUFACTURED IN 2005. AND YESTERDAY I DROVE IT FOR ABOUT 30 MILES. VOLVO IS FAMOUS FOR VARIOUS SAFETY FEATURES. HOWEVER, I FOUND THAT FOR MANY TIMES THE TURN SIGNAL LEVER DID NOT WORK WELL, WHICH REALLY SCARED ME AND ALMOST CAUSED CRASHES ON HIGHWAY 610 OF HOUSTON. THE SYMPTOM OF MALFUNCTION IS THAT SOMETIMES WHEN I MOVE THE TURN SIGNAL LEVER, IT EITHER DID NOT RESPOND OR SHOWED A "LAG". AND SOMETIMES THE SIGNAL KEPT FLASHING LEFT, EVEN I GAVE LEFT TURN TO THE RIGHT. I REPORTED THIS POTENTIAL MALFUNCTION TO YOU BECAUSE I JUST READ THE NEWS ON HTTP://WOT.MOTORTREND.COM/6669043/RECALLS/NHTSA-INVESTIGATES-2004-2005-VOLVO-XC90-FOR-FAULTY-LIGHTS-SIGNALS/INDEX.HTML, WHICH MAKES ME BELIEVE THAT IT IS NOT ONLY AN INDIVIDUAL CASE. HOPE YOU CAN HAVE A THOROUGH INVESTIGATION, FOR THE SAFETY OF ALL. THANK YOU. *TR
2005 VOLVO XC90 V8 TURN SIGNAL DOES NOT WORK PROPERLY. SOMETIMES NEED TO FLIP THE CONTROL BAR FOR MULTIPLE TIMES. FAIRLY DANGEROUS FOR CHANGING LANES OR TURNING TO LEFT OR RIGHT. PUSHING THE TURN SIGNAL CONTROLLER DOWNWARD MAKES THE SIGNAL WORK. PROBLEM IS CONSISTENT. *TR
2005 VOLVO XC90 T6, TRANSMISSION FAILED AFTER 64K MILES. TRANSMISSION FAILED AT HIGHWAY SPEEDS NEARLY CAUSING AN ACCIDENT AS THE VEHICLE SLOWED UNEXPECTEDLY ON I95 IN HEAVY TRAFFIC. TRANSMISSION FAILED AFTER A PROGRAM UPGRADE 3 WEEKS EARLIER. TRANSMISSION WAS SLIPPING AND TRANSMISSION SERVICE LIGHT APPEARED CAUSING THE VEHICLE…
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2005 VOLVO XC90 T6, TRANSMISSION FAILED AFTER 64K MILES. TRANSMISSION FAILED AT HIGHWAY SPEEDS NEARLY CAUSING AN ACCIDENT AS THE VEHICLE SLOWED UNEXPECTEDLY ON I95 IN HEAVY TRAFFIC. TRANSMISSION FAILED AFTER A PROGRAM UPGRADE 3 WEEKS EARLIER. TRANSMISSION WAS SLIPPING AND TRANSMISSION SERVICE LIGHT APPEARED CAUSING THE VEHICLE TO BE TOWED TO THE DEALER. DEALER UNABLE TO FIND ANY FAULT CODES BUT UPGRADED THE SOFTWARE, "HOPING THIS FIXES IT..." AFTER COMPLETE FAILURE, VEHICLE TAKEN ON FLATBED TO DON BEYER VOLVO WHO DIAGNOSED FAILURE AS A "TRANSMISSION FAILURE" THE DEALERSHIP OFFERED TO REPLACE TRANSMISSION AND SEVERAL OTHER PARTS AT NO COST. *TR
I HAVE A 2005 VOLVO XC90 IN WHICH MY LOW BEAM LIGHT JUST CUTS OUT. IT STARTED ABOUT A YEAR AGO. IT HAPPENS ALL OF THE TIME NOW. IT HAS NOT BEEN FIXED YET. I WAS LOOKING FOR POSSIBLE INFORMATION ON THIS PROBLEM AND LEARNED THAT AN INVESTIGATION IS UNDERWAY NOW AND THAT A RECALL MAY BE ISSUED. I JUST WANTED TO MAKE YOU AWARE OF…
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I HAVE A 2005 VOLVO XC90 IN WHICH MY LOW BEAM LIGHT JUST CUTS OUT. IT STARTED ABOUT A YEAR AGO. IT HAPPENS ALL OF THE TIME NOW. IT HAS NOT BEEN FIXED YET. I WAS LOOKING FOR POSSIBLE INFORMATION ON THIS PROBLEM AND LEARNED THAT AN INVESTIGATION IS UNDERWAY NOW AND THAT A RECALL MAY BE ISSUED. I JUST WANTED TO MAKE YOU AWARE OF ANOTHER VEHICLE WITH THE SAME PROBLEM. I ALSO LEARNED TODAY THAT A FRIEND WITH A VOLVO CROSSCOUNTRY WAGON HAD THE SAME PROBLEM UNTIL THE CEM WAS REPLACED. *TR
Official recalls
610V566000 · 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.
07V221000 · Electrical SYSTEM:12V/24V/48V Battery:cables
May 25, 2007
ON CERTAIN PASSENGER VEHICLES, IT HAS BEEN DETERMINED THAT WHILE DOING BATTERY MAINTENANCE THE JACK'S CRANK HANDLE CAN BE MISPLACED UNDER A BRACKET WHICH RETAINS THE BATTERY.
Consequence & remedy
Consequence: MISPLACEMENT OF THE JACK'S CRANK HANDLE CAN POSE A SAFETY RISK AS IT CAN RESULT IN A SHORT CIRCUIT OF THE BATTERY WHICH COULD THEN LEAD TO A FIRE.
Remedy: DEALERS WILL INSPECT AND ENSURE PROPER PLACEMENT OF THE JACK CRANK HANDLE AND A WARNING LABEL WITH APPROVED TEXT WILL BE AFFIXED TO THE BRACKET WHICH RETAINS THE BATTERY. THIS WARNING LABEL WILL INFORM AN OPERATOR NOT TO PLACE THE JACK CRANK HANDLE BETWEEN THE BRACKET AND THE BATTERY FREE OF CHARGE. THE RECALL BEGAN ON JULY 7, 2007. 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.
05V529000 · Electrical System:starter Assembly:solenoid
Nov 17, 2005
ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, DUE TO AN ERROR IN THE FACTORY ASSEMBLY INSTRUCTION, THE B+TERMINAL MAY BE IN CONFLICT WITH THE STARTER MOTOR SOLENOID. IF THIS OCCURS, THE CONFLICT BETWEEN THE B+TERMINAL AND THE STARTER MOTOR SOLENOID MAY DEVELOP INTO A SHORT CIRCUIT OF THE BATTERY CABLE TO GROUND.
Consequence & remedy
Consequence: SMOKE MAY APPEAR FROM UNDER THE HOOD AND IT MAY BE IMPOSSIBLE TO START THE CAR. IF THE SHORT CIRCUIT HAPPENS DURING DRIVING, ELECTRICAL POWER COULD BE LOST RESULTING IN THE WARNING LAMPS BEING DEACTIVATED. AN ELECTRICAL SHORT COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT AND INCREASE DISTANCE BETWEEN THE B+TERMINAL AND THE STARTER MOTOR SOLENOID BY ADJUSTING THE TERMINAL. THE RECALL BEGAN ON JANUARY 31, 2006. OWNERS MAY 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
4PE10025 · 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.
EA06006 · Volvo XC90 Battery Cable Failures
Opened Mar 21, 2006 · Closed Jun 14, 2007
Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery; Electrical SYSTEM:12V/24V/48V Battery:cables; Equipment:mechanical:accessory Scissor/screw/bottle Jack/lift
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Additional source detail variants (3)
Electrical SYSTEM:12V/24V/48V Battery:cables
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Electrical SYSTEM:12V/24V/48V Battery
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Equipment:mechanical:accessory Scissor/screw/bottle Jack/lift
DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY BRACKET AFTER BATTERY SERVICE/MAINTENANCE.DURING PE05-057 VOLVO INITIATED A SAFETY RECALL TO CORRECT THE FIRST CONDITION IN APPROXIMATELY 10,529 MY 2005 XC90 AND S80 VEHICLES EQUIPPED WITH SIX-CYLINDER ENGINES (NHTSA RECALL NO. 05V-529).IN A MAY 18, 2007 LETTER, VOLVO NOTIFIED NHTSA THAT IT WOULD BE CONDUCTING A SERVICE CAMPAIGN TO ADDRESS THE SECOND CONDITION IN APPROXIMATELY 42.211 MY 2005 XC90 VEHICLES BY INSPECTING THE JACK CRANK HANDLE FOR PROPER POSITIONING AND AFFIXING A WARNING LABEL ON THE BATTERY BRACKET TO WARN OPERATORS NOT TO PLACE THE HANDLE BETWEEN THE BATTERY AND BATTERY BRACKET (NHTSA RECALL NO. 07V-221). THE ACTIONS BY VOLVO ADDRESS BOTH CONDITIONS THAT POSE A RISK OF BATTERY CABLE FIRE IN THE SUBJECT VEHICLE POPULATION.THE AVAILABLE EVIDENCE DOES NOT INDICATE THAT THE OTHER BATTERY CABLE CONDITIONS REVIEWED DURING EA06-006 PRESENT HAVE RESULTED IN ANY FIRES IN THE SUBJECT VEHICLE POPULATION.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 IN ANY ONE OF THE ISSUES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
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.
PE05057 · Volvo XC90 Battery Cable Failures
Opened Nov 2, 2005 · Closed Mar 23, 2006
Status: closed (inferred from source dates) · Electrical SYSTEM:12V/24V/48V Battery:cables; Electrical System:starter Assembly; Electrical System:wiring; Electrical System:wiring:front Underhood
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Additional source detail variants (4)
Electrical SYSTEM:12V/24V/48V Battery:cables
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Electrical System:starter Assembly
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Electrical System:wiring:front Underhood
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.
Electrical System:wiring
THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE BATTERY CABLES IN APPROXIMATELY 9,000 MY 2005 VOLVO XC90 VEHICLES WITH SIX CYLINDER ENGINES THAT COULD RESULT IN A FIRE.VOLVO RECALLED THE AFFECTED VEHICLES TO ADDRESS THE POTENTIAL GROUNDING CONDITION (NHTSA RECALL #05V-529).THERE WERE 13 COMPLAINTS, INCLUDING 4 FIRES, AND 10 WARRANTY CLAIMS RELATED TO THE CONDITION ADDRESSED BY 05V-529.DURING PE05-057, VOLVO ALSO PROVIDED ODI WITH INFORMATION REGARDING THREE OTHER ISSUES RELATED TO THE BATTERY CABLE/TERMINALS IN MY 2005 XC90 VEHICLES:1) UNDER TORQUED BATTERY CABLE ATTACHING FASTENERS TO THE STARTER ALLEGEDLY CAUSING ENGINE STALLS AND MELTED PARTS IN THE ENGINE COMPARTMENT (APPLICABLE TO V8 ENGINES ONLY).2) THE JACK HANDLE MAY BE CRITICALLY MISPOSITIONED AGAINST THE POSITIVE BATTERY CABLE/POST ALLEGEDLY CAUSING FIRES IN SOME VEHICLES (APPLICABLE TO ALL XC90 VEHICLES).3) A POTENTIAL CHAFFING CONDITION OF THE POSITIVE BATTERY CABLE TO A SHARP EDGED SHEET METAL FLANGE IN THE REAR STORAGE COMPARTMENT. (APPLICABLE TO ALL XC90 VEHICLES).THE PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA06-006) TO ASSESS THE SCOPE, FREQUENCY AND POTENTIAL SAFETY CONSEQUENCES OF EACH OF THESE ISSUES.