Problems · NHTSA complaints
2003 Volvo XC90 problems
Owners filed 96 complaints about the 2003 Volvo XC90 with NHTSA between Apr 2003 and Jun 2022. The most-cited component is power train (51).
Complaints
96
Filed with NHTSA
Crashes
2
Reported by owners
Fires
2
Reported by owners
Injuries
6
People reported injured
Deaths
0
Reported to NHTSA
Complaints by component
One complaint can cite several components
- Power train51
- Electrical system18
- Suspension9
- Engine and engine cooling7
- Structure6
- Fuel system, gasoline6
- Equipment5
- Tires5
- Fuel/propulsion system4
- Steering4
- Air bags4
- Visibility3
- Electronic stability control (esc)3
- Service brakes, hydraulic3
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Data from NHTSA Complaints API · synced Oct 28, 2026NHTSA vehicle page
When complaints were filed
Does it get worse with age? Complaints per calendar year filed
6
9
1
3
8
18
14
14
7
2
4
2
6
0
0
0
0
0
1
1
View as table
| Model year | Complaints filed per calendar year |
|---|---|
| 2003 | 6 |
| 2004 | 9 |
| 2005 | 1 |
| 2006 | 3 |
| 2007 | 8 |
| 2008 | 18 |
| 2009 | 14 |
| 2010 | 14 |
| 2011 | 7 |
| 2012 | 2 |
| 2013 | 4 |
| 2014 | 2 |
| 2015 | 6 |
| 2016 | 0 |
| 2017 | 0 |
| 2018 | 0 |
| 2019 | 0 |
| 2020 | 0 |
| 2021 | 1 |
| 2022 | 1 |
Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.
Top problems in owners’ words
Verbatim from NHTSA complaints, newest first
Power train
51 reports
“TRANSFER CASE KEEPS LOCKING UP AND MESSING UP. IN PAST YEAR PAID 1500 TWO TIMES TO REPLACE TRANSFER CASE AND IS NOW IN SHOP AGAIN FOR SAME REASON. TRANSFER CASE LOCKING UP. FEB 2020, JULY 2020, AND NOW JANUARY 2021 FEB GOING SPEED OF 35-40, JULY ON HIGHWAY SPEED OF 70 IN MIDDLE OF FREEWAY, AND JAN SPEED OF 35”
Electrical system
18 reports1 fire
“DRIVING THE XC90 AND SUDDENLY THERE IS A HUGE THUMP AND CLICKING FROM THE DASHBOARD. ALL THE DIALS AROUND THE SPEDOMETER STOP WORKING.. IF WE KEEP DRIVING THERE ARE MORE THUMPS AND WE QUICKLY LOSE ENGINE POWER - IT IS EXTREMELY SCARY WHEN IT HAPPENS.. ALL THE LIGHTS COME ON (INSIDE THE CAR), DASHBOARD GOES DEAD ETC ETC. IT IS EXTREMELY DANGEROUS .. IT HAPPENED TO USE A NUMBER OF TIMES WITH 3 CHILDREN IN THE CAR. IT HAS OCCURRED WHEN WE WERE DRIVING ON THE HIGHWAY, 2-3 TIMES, IT HAS OCCURRED ON SHORT TRIPS - IT HAPPENS AT SEEMINGLY RANDOM TIMES, USUALLY AFTER DRIVING FOR OVER 30 MINUTES, BUT THEN YESTERDAY IT HAPPENED ON A TRIP JUST DOWN TO THE PARK, NOT 5 MINUTES DOWN THE ROAD.. ON THIS OCCASION THE CAR HAD BEEN SITTING IN THE SUN FOR A WHILE (MAYBE HEAT RELATED?). IT HAS HAPPENED IN HOT WEATHER, COLD WEATHER .. WE ARE IN CONSTANT FEAR WHEN DRIVING THE CAR. I HAVE CONTACTED VOLVO AUSTRALIA ABOUT THE ISSUE BUT THEY SAID THEY HAVE NO RESPONSIBILITY, THAT THERE IS NO RECALL FOR THE PROBLEM AND DIDN'T WANT TO HELP AT ALL!! I SEE A LOT OF PEOPLE HAVE THIS SAME PROBLEM, IS VOLVO NOT GOING TO FIX IT UNTIL SOMEONE IS KILLED??? WHAT WILL IT TAKE!?!?!?! IT IS A JOKE ! WE…”
Suspension
9 reports
“LEAVING A PARKING LOT AND HEARD LOUD SOUND CAR WOULDN'T MOVE. VOLVO SAYS THE FOLLOWING IS BROKEN: LOWER CONTROL ARM, CV AXLE, ROTOR AND DAMAGED RIM. WE HAD BEEN PARKED AND WERE ATTEMPTING TO LEAVING PARKING LOT(.BARELY MOVING) COULD HAVE BEEN KILLED IF THIS HAPPENED AT HIGHER SPEED. WE HAVE CONSTANTLY SPENT MONEY ON THIS VEHICLE AND I FEEL IT IS UNSAFE AND THAT WHEN THE RECALLS WERE MADE THERE COULD HAVE ALREADY BEEN A FRACTURE. THIS CAR IS ONLY DRIVEN TO WORK AND HOME ON A REGULAR BASIS. NO ROUGH ROADS. WE HAVE NOT CAUSED ANY DAMAGE. THIS WEBSITE DOES NOT ALLOW PROPER SELECTION UNDER VOLVO AND MAKE TO ALLOW SELECTION OF THE SUSPENSION/CONTROL ARM / ROTORS / AXLE / TIRE RIMS / BALL JOINT, ALL OF WHICH WERE DAMAGED IN THIS 4 MPH ACCIDENT. HAD THIS HAPPENED AT 65 MPH I HAVE NO DOUBT ME AND MY FAMILY WOULD NOT HAVE SURVIVED. *TR”
Engine and engine cooling
7 reports
“MY 2003 VOLVO XC90 HAS BEEN TO THE DEALER SEVERAL TIMES INCLUDING OVER 3 TIMES FOR SAME PROBLEM WHEN I PURCHASED THE VEHICLE IN 2006. ALL RECALLS HAVE BEEN FIXED, FRONT AXLE, WIPERS ETC. I HAVE PURCHASED 4 SETS OF TIRES, TIRES BOSTON VOLVO INSTALLED AND MY 17 YEAR OLD SON RECEIVED A COMPLETE BLOW OUT BECAUSE WRONG SIZE TIRES. I CONTINUE TAKING TO SAME DEALER AND SINCE OWNING THE CAR HAVE HAD THE SAME NOISES IN FRONT OF CAR. BOSTON VOLVO HAS STATED IN OCTOBER AND SINCE OWNING THE VEHICLE CAN FIND NOTHING WRONG, APRIL DIAGNOSED WITH NEED NEW DRIVE SHAFT AFTER HAVING CAR FOR 2 DAYS BUT COULD NOT REALLY FINE ANYTHING BUT DRIVE SHAFT. A STRONG FUEL SMELL STATED FUEL PUMP DOES NOT NEED TO BE CORRECTED. I NEED NEW MUFFLER AND TAKING TO MY OWN MECHANIC THE REAL ISSUE IS TRANSMISSION SERVICE URGENT AND NEED NEW TRANSMISSION. VOLVO DID NOT DIAGNOSE THIS PROBLEM AND MY SON IS DRIVING THE CAR! MY SON IS DRIVING A LEMON THAT IS A DANGER TO HIMSELF. TAKING TO VOLVO DOES NOTHING, THEY CANNOT EVEN DIAGNOSE AND GIVE WRONG INFO GIVEN TO ME. I AM CURRENTLY UP TO OVER $8,000 IN DAMAGES AND STILL OWE ON THIS LEMON. I NEED NEW TRANSMISSION, MUFFLER, STILL CAR VIBRATES AND FRONT END…”
Structure
6 reports
“VEHICLE DRAINS WATER ON TO FRONT PASSENGER FLOOR, AND OCASSIONAL DRIVER SIDE AFTER IT RAINS. IT IS A KNOW PROBLEM THAT A CLASS ACTION SUIT WAS WON IN NEW JERSEY, INCLUDING 5 OTHER STATES. THE WATER IS FROM CLOGGED DRAIN TUBES IN SUNROOF AND SOMETIMES SHRINKIAGE OF DRAIN TUBE THAT DISLODGES. VEHICLE NOW HAS A MUSTY SMELL FROM THE FREQUENT WATER IN THE VEHICLE. NOT SURE IF HIGH MOISTURE INSIDE HAS CAUSED MY CD PLAYER TO MALFUNCTION. ALSO HAVE A SHORT IN ELECTRICAL SYSTEM THAT CAUSE ME TO REPLACE 3 BATTERIES IN THE VEHICLE. ALSO THE SUNROOF MOTOR SHORTED OUT MAKING IT DIFFICULT TO REPLACE THE DRAINAGE TUBES THAT WOULD HELP CORRECT THE WATER ISSUES. HOPE SOMEONE CAN HELP.”
Fuel system, gasoline
6 reports1 related recall
“TL* THE CONTACT OWNS A 2003 VOLVO XC90. THE CONTACT STATED THAT GASOLINE FUMES WERE EMITTED INTO THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE TECHNICIAN DIAGNOSED THAT THERE WAS A LEAK IN THE FUEL PUMP AND IT NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED NO ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN NHTSA RECALL CAMPAIGN 09V483000 (FUEL SYSTEM). THE VEHICLE WAS REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 108,000. THE CURRENT MILEAGE WAS 109,000.”
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 28, 2026
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.