Owner report · 2004 model year

2004 Volvo XC90

Crash-test image: National Highway Traffic Safety Administration (NHTSA), U.S. Department of Transportation.

The Verdict

Worst problem area

Electrical

Electrical leads by volume: 158 of 462 complaints (34%) mention it. Complaints mentioning Airbags & Restraints include more reported injuries (3) than those mentioning any other identified area.

Complaints filed rose from 93 in 2003 to 462 in 2004.

Data last changed Nov 7, 2026. Sources: NHTSA complaints and recalls, EPA fuel economy data. Methodology

At a glance

NHTSA complaints: 462
Recall campaigns: 6
EPA fuel cost per year: $4,050–$4,850
Combined MPG: 16–19

Complaints by model year

932003
4622004
2232005
532006

Where owners report problems

Electrical158 (34%)
Transmission & Drivetrain145 (31%)
Fuel System77 (17%)
Engine52 (11%)
Airbags & Restraints38 (8%)
Visibility & Lighting37 (8%)

Cost, Fuel Economy & Complaint History

Fuel cost, fuel economy, and complaint history by model-yearScroll sideways to see all 4 years. Fuel figures show the range across trims for years with more than one EPA-rated configuration.Also cataloged for 2004: 1 configuration(s) of a different vehicle class, excluded from the comparison bar only (but included in the figures above).
Category	2003	2004	2005	2006	vs. 2004 Sport Utility Vehicle - 4WD
Annual fuel cost ($)	4,300–4,850	4,050–4,850	4,300–5,150	4,300–5,150
Combined MPG	16–18	16–19	15–18	15–18
City / Highway MPG	14–16 / 19–22	14–16 / 19–22	13–16 / 19–21	13–15 / 19–21
CO₂ tailpipe (g/mi)	494–555	468–555	494–592	494–592
Complaints filed	93	462	223	53	Not compared
Recalls issued	5	6	6	3	Not compared
Crash-involved complaints	2	9	1	4	Not compared
Fire-involved complaints	2	3	3	4	Not compared
Injuries reported	6	8	1	3	Not compared
Deaths reported	0	0	0	0	Not compared
Configurations compared	2	2	3	2

Common questions

How many recalls does the 2004 Volvo XC90 have?

6 NHTSA recall campaigns as of Nov 7, 2026. Check your VIN with NHTSA to see whether one applies to your car.

What is the most common complaint about the 2004 Volvo XC90?

Electrical: 158 of 462 NHTSA complaints (34%) mention it.

What gas mileage does the 2004 Volvo XC90 get?

EPA rates it 16–19 MPG combined.

How much does it cost to fuel a 2004 Volvo XC90?

EPA estimates $4,050–$4,850 a year in fuel costs, using EPA's assumptions.

Similar Vehicles

EPA-Rated Configurations (3)

Every EPA-rated configuration on this page, one row each.A number tagged (low) or (high) is this page’s own cost-table figure of that name, above.
Configuration	Transmission	Cylinders	Displacement	Drivetrain	Fuel Type	Vehicle Class	City	Highway	Combined	Annual Fuel Cost	CO₂
Configuration 1	Automatic (S5)	5	2.5L	Front-Wheel Drive	Premium	Sport Utility Vehicle - 2WD	16 mpg (high)	22 mpg (high)	19 mpg (high)	$4,050 (low)	468 g/mi (low)
Configuration 2	Automatic (S5)	5	2.5L	4-Wheel or All-Wheel Drive	Premium	Sport Utility Vehicle - 4WD	16 mpg (high)	22 mpg (high)	18 mpg	$4,300	494 g/mi
Configuration 3	Automatic (S4)	6	2.9L	4-Wheel or All-Wheel Drive	Premium	Sport Utility Vehicle - 4WD	14 mpg (low)	19 mpg (low)	16 mpg (low)	$4,850 (high)	555 g/mi (high)

Complaints by Category

Complaints by category, in the same fixed order on every page
Category	Complaints	Crash-Involved	Fire-Involved	Injuries
Engine	52	0	0	0
Transmission & Drivetrain	145	1	0	0
Fuel System	77	0	0	1
Electrical	158	3	2	1
Brakes	28	3	0	1
Steering	20	1	0	0
Suspension, Wheels & Tires	36	0	0	0
Airbags & Restraints	38	3	0	3
Driver Assistance & Speed Control	18	1	0	0
Body, Seats & Latches	20	0	1	2
Visibility & Lighting	37	0	0	0
Other	21	0	0	0

A complaint that names more than one category is counted in each, so the rows can add up to more than the total number of complaints.

Recalls (6)

EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)
Campaign 10V566000 · Nov 8, 2010
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 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.
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
Campaign 09V483000 · Dec 18, 2009
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 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.
STEERING:LINKAGES:TIE ROD ASSEMBLY
Campaign 06V155000 · May 5, 2006
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:WINDSHIELD WIPER/WASHER
Campaign 06V144000 · Apr 28, 2006
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
Campaign 03V434000 · Nov 4, 2003
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:REAR/OTHER
Campaign 03V391000 · Oct 10, 2003
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.