Recalls
6campaigns
1 electrical · 1 fuel pump · 1 steering
Source: NHTSA
Complaints
462filed
Owner reports, 2003–2012 shown
Source: NHTSA ODI
Fuel economy
19mpg combined
$3,437/yr at this week's prices
Source: EPA · EIA
Specs
2.5 L 5-cyl· 5-speed automatic
3 engine and transmission configurations
Source: NHTSA vPIC
Recalls (6)
NHTSA lists 6 recall campaigns for the 2004 Volvo XC90. Check whether yours was repaired with NHTSA's free VIN lookup ↗
Only NHTSA and your automaker know whether your specific car was repaired. PlainVIN shows every recall campaign listed for a model year, with the official text and how many cars have been fixed so far.
Check on NHTSA ↗Listed for 2004 Volvo XC90. Not checked against your VIN.
760 PORTABLE AUTOMOTIVE GPS UNITS/GARMIN
Equipment · electrical · navigational system(global positioning system)
Official NHTSA text
- Summary
- VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
- 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.
Repair progress not yet reported416 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 10V566000
Listed for 2004 Volvo XC90. Not checked against your VIN.
FUEL PUMP LEAK
Fuel system, gasoline · delivery · fuel pump
Official NHTSA text
- Summary
- 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
- 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.
Repair progress not yet reported158,733 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 09V483000
Listed for 2004 Volvo XC90. Not checked against your VIN.
TIE ROD BALL JOINT FRACTURE
Steering · linkages · tie rod assembly
Official NHTSA text
- Summary
- 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
- 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.
Repair progress not yet reported126,743 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 06V155000
Listed for 2004 Volvo XC90. Not checked against your VIN.
WINDSHIELD WIPER ARM
Visibility · windshield wiper/washer
Official NHTSA text
- Summary
- 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
- 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.
Repair progress not yet reported122,431 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 06V144000
Listed for 2004 Volvo XC90. Not checked against your VIN.
VOLVO/FRONT WHEEL SPEED SENSOR
Wheels
Official NHTSA text
- Summary
- ON CERTAIN SPORT UTILITY VEHICLES, THE FRONT WHEEL SPEED SENSORS MAY BE DEFECTIVE, CAUSING AN ERRONEOUS WHEEL SPEED SIGNAL.
- 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.
Repair progress not yet reported2,586 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 03V434000
Listed for 2004 Volvo XC90. Not checked against your VIN.
VOLVO/SEAT BELT ATTACHMENTS
Seat belts · rear/other
Official NHTSA text
- Summary
- 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
- 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.
Repair progress not yet reported18,692 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 03V391000
PlainVIN shows public government records for education. It isn't a vehicle inspection or legal advice. Check your own VIN with NHTSA or your dealer.
Owner complaints (462)
462 complaints filed with NHTSA (owner reports, not verified findings). The electrical system is mentioned most often.
9involved a crash
3involved a fire
8injuries reported
0deaths reported
As reported by owners in their complaints. These are reports, not NHTSA findings.
Most-reported components
| Component | Complaints | % of 462 |
|---|---|---|
| Electrical system | 158 | 34.2% |
| Power train | 145 | 31.4% |
| Fuel system | 43 | 9.3% |
| Fuel/propulsion system | 34 | 7.4% |
| Exterior lighting | 32 | 6.9% |
| Air bags | 31 | 6.7% |
| Engine | 28 | 6.1% |
| Engine and engine cooling | 24 | 5.2% |
| Suspension | 23 | 5% |
| Steering | 20 | 4.3% |
How 2004 compares with other XC90 years
Best and worst XC90 years →200393
2004462
2005223
200653
200738
200829
20097
201012
201119
20123
| Model year | Complaints | Recall campaigns |
|---|---|---|
| 2003 | 93 | 5 |
| 2004 | 462 | 6 |
| 2005 | 223 | 6 |
| 2006 | 53 | 3 |
| 2007 | 38 | 2 |
| 2008 | 29 | 3 |
| 2009 | 7 | 1 |
| 2010 | 12 | 3 |
| 2011 | 19 | 1 |
| 2012 | 3 | 0 |
This year (2004)Other yearsStill collecting reports
Counts are owner reports, not failure rates. Higher sales years tend to draw more reports. Owners are still filing reports for recent model years, so these counts will grow. Source: NHTSA ODI, retrieved Oct 6, 2026.
Fuel economy: up to 19 mpg combined
19
mpg combined
16
city
22
highway
- EPA annual fuel cost
- $4,350
- CO₂ tailpipe
- 468 g/mi
- EPA class
- Sport Utility Vehicle -
What it costs you to run
$3,437per year
$286per month
789gallons a year
Miles ÷ 19 mpg × $4.354 (EIA US average regular, week of Oct 5, 2026, all taxes included). Source: EPA · EIA.
EPA label estimates from lab tests; your mileage will vary.
Specs by configuration
| Engine · transmission | Drive | City / Hwy / Comb | EPA $/yr | CO₂ g/mi |
|---|---|---|---|---|
| 2.5 L 5-cyl · 5-speed automatic | Front-Wheel Drive | 16 / 22 / 19 | $4,350 | 468 |
| 2.5 L 5-cyl · 5-speed automatic | 4-Wheel or All-Wheel Drive | 16 / 22 / 18 | $4,550 | 494 |
| 2.9 L 6-cyl · 4-speed automatic | 4-Wheel or All-Wheel Drive | 14 / 19 / 16 | $5,150 | 555 |
Source: EPA fuel economy data, retrieved Oct 6, 2026. Configurations are listed when EPA and NHTSA records match.
Looking at a 2004 XC90 for sale?
Print a one-page buyer's checklist: each recall campaign with a box to tick when the seller shows proof of repair, the top complaint areas to inspect, crash stars, MPG, and a link back to this page.
Where to next
2004 Volvo XC90 FAQ
How many recalls does the 2004 Volvo XC90 have?
NHTSA lists 6 recall campaigns: 10V566000 (electrical), 09V483000 (fuel pump), 06V155000 (steering), 06V144000 (visibility), 03V434000 (wheel), 03V391000 (seat belt). Use NHTSA's VIN lookup to see whether a specific car was repaired.
What are the most common 2004 Volvo XC90 problems?
Owners filed 462 complaints with NHTSA. Electrical system (158), Power train (145), Fuel system (43) are mentioned most. These are owner reports, not verified findings.
What mpg does the 2004 Volvo XC90 get?
EPA rates the 2.5 L 5-cyl · 5-speed automatic version at 16 city, 22 highway and 19 combined mpg. Other configurations are listed in the fuel economy section.
How does the 2004 XC90 compare with other years?
Among the 2003–2012 Volvo XC90 model years at least five years old, the 2012 drew the fewest complaints (3) and the 2004 the most (462). The 2004 drew 462. Counts are owner reports, not failure rates.
How this page was madeSources, processing, limits, review and changes
Data sources
- NHTSA recalls by vehicle
Retrieved Oct 6, 2026 - US DOT recall completion rates (data.transportation.gov)
Retrieved Oct 6, 2026 - NHTSA ODI owner complaints
Retrieved Oct 6, 2026 - NHTSA NCAP 5-Star Safety Ratings
Retrieved Oct 6, 2026 - EPA fuel economy data (licence confirmation pending)
Retrieved Oct 6, 2026 - EIA weekly retail gasoline prices
Weekly, all taxes included
Processing
- Complaints are counted per component. One complaint can list several, so component totals add up to more than the total.
- Fuel cost = miles per year ÷ EPA combined mpg × EIA weekly price for your region.
Limitations
- Complaint counts are owner reports, not verified findings or failure rates. There is no sales denominator.
- Recall campaigns are listed for the model year. Only NHTSA and the automaker know whether a specific car was repaired.
- Recent model years are still collecting reports.
Review
Data compiled automatically from the official files listed here.
Changelog
- 2026-10-06 Data refreshed from the official files.
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