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Research · Sport Utility Vehicle - 2WD

2004 Volvo XC90Recalls, problems, MPG & safety

NHTSA lists 6 safety recalls and 462 owner complaints for the 2004 Volvo XC90. Most complaints involve electrical system (158) and power train (145). The EPA rates it 16–19 mpg combined.

Check a VINAdd to my garage
Combined MPG
16–19mpg
EPA · 3 versions
NHTSA overall
—
Not rated by NCAP
Safety recalls
6campaigns
Latest Nov 2010
Owner complaints
462
Top: electrical system
Fuel cost / yr
$4,200est.
EPA estimate, best version
01 —Recalls

Safety recalls

6 NHTSA campaigns · applies to some vehicles, check your VIN

Equipment: navigational system(global positioning system)

Free remedy

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

EquipmentReported Nov 8, 2010NHTSA 10V566000

Fuel system

Free remedy

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.

Fuel system, gasolineReported Dec 18, 2009NHTSA 09V483000

Steering: tie rod assembly

Free remedy

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.

SteeringReported May 5, 2006NHTSA 06V155000
See all 6 recalls with remedies
Data from NHTSA Recalls API · synced Oct 29, 2026 · All recall detailsNHTSA vehicle page
02 —Complaints

Owner complaints by component

462 complaints filed with NHTSA · Dec 2003 – Mar 2025
  1. Electrical system158
  2. Power train145
  3. Fuel system, gasoline40
  4. Fuel/propulsion system34
  5. Exterior lighting32
  6. Air bags31
  7. Engine28
  8. Engine and engine cooling24
  9. Suspension23

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.

By model year

Complaints for each XC90 model year we’ve synced.

View as table
Model yearNHTSA complaints
200396
2004462
2005223
200653
200738
200829
20097
201012
201119
20123
201311
20144
2016197
201781
201852
201942
202034
202117
Crashes reported
9
Fires reported
3
Injuries reported
8
Deaths reported
0
Data from NHTSA Complaints API · synced Oct 29, 2026 · Full problem breakdownNHTSA vehicle page
03 —Common problems

What owners report most

Verbatim excerpts from NHTSA complaints, by component

Electrical system

158 reports3 crashes2 fires
“Instrument panel shuts down while driving on street. I believe it is the central electronic module that fails. It has happened numerous times and it is unsafe to drive without a speedometer, tachometer, odometer fuel gauge, and temperature gauge. It has now stopped altogether. Gauges just sit there and bounce”
Owner complaint to NHTSAFiled Mar 9, 2025Electrical systemODI 11647245

Power train

145 reports1 crash
“I AM CONCERNED THESE 2 ISSUES MAY POSE A SAFETY RISK. I RECENTLY PURCHASED THIS CAR FROM A FRIEND AND HAVE HAD IT ABOUT A MONTH. I NOTICE THE STEERING IS VERY STIFF AND DIFFICULT TO MANEUVER. I WAS TRYING TO FIND OUT IF THERE WERE ANY RECALLS ON THIS BUT HAVING NO LUCK. ALSO, WHEN THE CAR IS IN GEAR "DRIVE", WHEN STOPPED ON AN INCLINE (EVEN THE SLIGHTEST HILL) I NOTICE THAT WHEN I TAKE MY FOOT OFF THE BRAKE PEDAL THE CAR ROLLS BACKWARDS! IT SHOULDN'T DO THAT. THE TRANSMISSION NOTICE ON THE DASH IS SAYING IT NEEDS SERVICE BUT MY FRIEND I BOUGHT IT FROM SAID SHE HAD IT CHECKED TWICE AND WAS TOLD THERE IS NO TRANSMISSION ISSUE. IS THERE A RECALL ON POWER-TRAIN/TRANS PARTS? THE CAR SHOULD NOT ROLL BACKWARDS WHEN IN GEAR "DRIVE", EVEN IF I AM STOPPED ON A HILL. EVEN A SLIGHT INCLINE AND THE CAR ROLLS BACK. NOT NORMAL. THANK YOU FOR ANY AND ALL HELP YOU CAN OFFER. THIS ISN'T AN "INCIDENT" BUT I DO NOT KNOW WHO ELSE TO CONTACT FOR HELP. *TR”
Owner complaint to NHTSAFiled Apr 14, 2020Steering, Power trainODI 11321055

Fuel system, gasoline

40 reports
“The contact owns a 2004 Volvo XC90. The contact stated that after refueling the vehicle, his wife noticed an abnormally strong gasoline odor. The contact's wife was able to continue driving the vehicle; however, the failure would return after refueling or on rainy days. The contact related the failure to NHTSA Campaign Number: 09V483000 (Fuel System, Gasoline) however, the VIN was not included. The dealer and the manufacturer were notified of the failure and informed the contact that they could not assist as the VIN was not under recall. The vehicle was not diagnosed or repaired. The failure mileage was approximately 30,000.”
Owner complaint to NHTSAFiled Nov 9, 2022Fuel system, gasolineODI 11492882
All 2004 XC90 problemsSend a problem to a mechanic on findmechanic.ai
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 29, 2026
04 —Key specs

Engines, transmissions & drive

3 versions rated by the EPA
EPA class
Sport Utility Vehicle - 2WD, Sport Utility Vehicle - 4WD
Engines
2.5L 5-cyl turbo · 2.9L 6-cyl turbo
Transmissions
Automatic (S5) · Automatic (S4)
Drive
Front-Wheel Drive · 4-Wheel or All-Wheel Drive
Fuel
Premium Gasoline

Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.

Data from EPA fueleconomy.gov · synced Oct 29, 2026EPA listing
05 —Fuel economy

EPA fuel economy by version

City / highway / combined, annual fuel cost and CO₂
EPA
VersionCityHwyComb.Fuel / yrCO₂ g/mi
XC90 FWD
Auto (S5), 5 cyl, 2.5 L, Turbo · Front-Wheel Drive
162219$4,200468
XC90 AWD
Auto (S5), 5 cyl, 2.5 L, Turbo · 4-Wheel or All-Wheel Drive
162218$4,400494
XC90 AWD
Auto (S4), 6 cyl, 2.9 L, Turbo · 4-Wheel or All-Wheel Drive
141916$5,000555
  • XC90 FWD
    Auto (S5), 5 cyl, 2.5 L, Turbo
    16 city · 22 hwy · $4,200/yr
    19
    mpg comb.
  • XC90 AWD
    Auto (S5), 5 cyl, 2.5 L, Turbo
    16 city · 22 hwy · $4,400/yr
    18
    mpg comb.
  • XC90 AWD
    Auto (S4), 6 cyl, 2.9 L, Turbo
    14 city · 19 hwy · $5,000/yr
    16
    mpg comb.
Estimate your fuel costCost of ownership
Data from EPA fueleconomy.gov · synced Oct 29, 2026 · Fuel cost is EPA’s annual estimate (15,000 mi, 55% city)
06 —Safety

NHTSA 5-Star Safety Ratings

1 tested variant
NHTSA has not published 5-Star Safety Ratings for the 2004 Volvo XC90 as of Oct 29, 2026.
Data from NHTSA NCAP Safety Ratings API · synced Oct 29, 2026Vehicle 1007
07 —Maintenance

Maintenance basics

General guidance, not the OEM schedule. Check your owner’s manual.
General guidance
ItemMilesTimeNote
Engine oil & filter5,000–10,000 mi6–12 monthsFollow the oil-life monitor if fitted
Tire rotation5,000–7,500 miEvery oil changeCheck pressure monthly
Engine air filter15,000–30,000 mi1–2 yearsSooner in dusty areas
Cabin air filter15,000–25,000 mi1–2 years
Brake fluid—2–3 yearsAbsorbs moisture over time
Coolant60,000–100,000 mi5–10 yearsLong-life coolants last longer
Spark plugs60,000–100,000 mi—Iridium/platinum plugs at the long end
12V battery—3–5 yearsHeat shortens battery life
  • Engine oil & filter5,000–10,000 mi
    6–12 months
  • Tire rotation5,000–7,500 mi
    Every oil change
  • Engine air filter15,000–30,000 mi
    1–2 years
  • Cabin air filter15,000–25,000 mi
    1–2 years
  • Brake fluid—
    2–3 years
  • Coolant60,000–100,000 mi
    5–10 years
  • Spark plugs60,000–100,000 mi
    —
  • 12V battery—
    3–5 years
Typical intervals for modern cars. Severe service (towing, short trips, extreme heat or cold) shortens them.
09 —FAQ

2004 XC90 questions

How many recalls does the 2004 Volvo XC90 have?

6 safety recalls as of Oct 29, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.

What are the most common 2004 Volvo XC90 problems?

Owners filed 462 complaints with NHTSA. The most-cited components are electrical system (158), power train (145), fuel system, gasoline (40). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.

What MPG does the 2004 Volvo XC90 get?

The EPA rates the 2004 Volvo XC90 at 16–19 mpg combined, depending on engine and drivetrain (3 versions rated).

Data from NHTSA & EPA · synced Oct 29, 2026