Problems · NHTSA complaints

2004 Volvo XC90 problems

Owners filed 462 complaints about the 2004 Volvo XC90 with NHTSA between Dec 2003 and Mar 2025. The most-cited component is electrical system (158).

Complaints
462
Filed with NHTSA
Crashes
9
Reported by owners
Fires
3
Reported by owners
Injuries
8
People reported injured
Deaths
0
Reported to NHTSA
01 —By component

Complaints by component

One complaint can cite several components
  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
  10. Steering20
  11. Vehicle speed control17
  12. Structure14
  13. Electronic stability control (esc)11
  14. Wheels10

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 29, 2026NHTSA vehicle page
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
20031
200414
20058
200613
200710
200847
200957
201084
201158
201231
201320
201430
201528
201617
201712
20188
20197
20202
20217
20223
20233
20241
20251

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.

03 —Owner reports

Top problems in owners’ words

Verbatim from NHTSA complaints, newest first

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 reports1 related recall
“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

Fuel/propulsion system

34 reports
“Unsure of what the issue is with the vehicle but smells like gas in my garage and I found a recall I was never notified about I moved from Washington to Las Vegas and never received any info regarding the fuel pump recall as well as a noise that’s been going on for a year now when I drive at 60 miles an hour I’ve had it looked at and no one seems to know what that issue is”
Owner complaint to NHTSAFiled Nov 22, 2024Electrical system, Engine, Fuel/propulsion systemODI 11626848

Exterior lighting

32 reports
“While driving on the highway "SRS urgent" text came on, also hear clicking sounds under dash on driver side, then dashboard indicator lights completely disappear (speed, fuel, temperature, etc) . Extremely hot under driver side dash. Fortunately, still able to steer and brake. This has happened twice now. Mechanic believes most likely CEM failure or DIM failure. My vehicle also has a wet A-pillar fabric (Volvo forums indicate possible cause of failure). I removed drivers A-pillar and found a clogged drain tube from the sunroof. However, did not notice any obvious signs of water inside the vehicle, though it hasnt rained for over a month when this happened.”
Owner complaint to NHTSAFiled Nov 12, 2021Electrical system, Exterior lighting, EngineODI 11440237

Air bags

31 reports3 crashes
“WHILE I'M MOTION THE SRS AIRBAG LIGHT CAME ON TRANSMISSION URGENT LIGHT CAME ON AND ABS LIGHT THE BATTERY KEEPS BUBBLING LIKE ITS GONE BLOW UP IN MY TRUNK I HAVE TO JUMP IT OFF EVERY MORNING I PAID ALOT FOR THIS SUV CAN YOU PLEASE HELP ME KEEP MY ONLY CAR IN WORKING ORDER I HAVE HAD ALL MAINTAINS DONE IN PAST NOW THE COOLANT SYSTEM IS LEAKING WHAT IS GOING ON WITH THIS VOLVO XC90 T6 AWD [XXX] ' *PM”
Owner complaint to NHTSAFiled Dec 5, 2019Power train, Electrical system, Air bagsODI 11287254
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 29, 2026

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