RecallRepo

2004 Volvo XC90 Recalls

Recalls on record Updated July 2026

The 2004 Volvo XC90 has 6 NHTSA recall campaigns affecting an estimated 429,601 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 669 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.

Recall campaigns

EQUIPMENT 10V566000 2010-11-08 416 affected
Defect

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…

FUEL SYSTEM, GASOLINE 09V483000 2009-12-18 158,733 affected
Defect

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…

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.

STEERING 06V155000 2006-05-05 126,743 affected
Defect

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.

VISIBILITY 06V144000 2006-04-28 122,431 affected
Defect

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.

WHEELS 03V434000 2003-11-04 2,586 affected
Defect

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.

SEAT BELTS 03V391000 2003-10-10 18,692 affected
Defect

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.

Complaints by component

ELECTRICAL SYSTEM
152
2crashes1fires1injuries
POWER TRAIN:AUTOMATIC TRANSMISSION
102
POWER TRAIN
37
FUEL/PROPULSION SYSTEM
34
FUEL SYSTEM, GASOLINE
32
1injuries
EXTERIOR LIGHTING
30
ENGINE
28
AIR BAGS
26
1crashes
VEHICLE SPEED CONTROL
16
1crashes
STEERING
15
1crashes
Total complaints669

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“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…”

ELECTRICAL SYSTEM · reported 2025-03-06

“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…”

FUEL/PROPULSION SYSTEM · reported 2024-11-08

“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…”

ENGINE · reported 2024-11-08

“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…”

ELECTRICAL SYSTEM · reported 2024-11-08

“Few days ago I came home, parked the car inside the garage and went inside. An hour later I went to the garage for something and noticed a very strong gasoline odor coming from the car. It is not coming from the reservoir and I did not put any fuel recently, so it can't be explained with a fuel…”

FUEL/PROPULSION SYSTEM · reported 2023-05-09

“The rear right door cannot be open from inside the car. It opens fine from outside. I am aware there is a child safety lock, but in this case the problem is somewhere else. Regardless of the child safety lock position, the door cannot be open. This is a hazard, because in case oof an accident the…”

STRUCTURE:BODY · reported 2023-04-07

“Unknown..but water accumulated under the passenger seat under the amp and electrical components after a storm or rainy day.and its a lot of water when I brake I can hear a water fall..and water rushing and moving along the bottom. Of the car as I am steering im worried that the wiring and…”

ELECTRICAL SYSTEM · reported 2023-03-10

“The contact owns a 2004 volvo xc90. The contact stated that after his wife started the vehicle, she smelled the odor of gasoline. The contact had been advised by his wife that the vehicle was taking longer to start up and sometimes required two or three attempts to start the vehicle. The contact…”

FUEL SYSTEM, GASOLINE · reported 2022-09-17

Defect investigations

Investigation PE05064 Opened 2005-12-02 · closed 2006-05-10

WINDSHIELD WIPER ARM PERFORMANCE

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.…

Investigation PE09039 Opened 2009-08-31 · closed 2009-12-22

FUEL PUMP LEAK

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER…

Investigation PE09039 Opened 2009-08-31 · closed 2009-12-22

FUEL PUMP LEAK

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER…

Investigation PE09039 Opened 2009-08-31 · closed 2009-12-22

FUEL PUMP LEAK

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER…

Investigation PE09039 Opened 2009-08-31 · closed 2009-12-22

FUEL PUMP LEAK

VOLVO HAS DETERMINED THAT DUE TO EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATES AND TEMPERATURE CYCLING) AND VARYING FUEL QUALITY, THE FUEL PUMP FLANGE IN THE XC90 VEHICLES CAN DEVELOP CRACKS.OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL SEEPAGE.DUE TO SIMILAR MATERIAL USAGE, THIS ISSUE ALSO AFFECTS OTHER…

Investigation PE10025 Opened 2010-07-20 · closed 2010-11-22

Central Electronic Module Failure

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…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Volvo XC90 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.