Is the 2004 Volvo XC90 a bad year?
462 owner complaints to NHTSA. Transmission complaints: 145, 15× a quiet XC90 year.
Consider selling
Half of all transmission complaints about the 2004 Volvo XC90 were filed between 62k and 107k miles. You're at 78,000 miles.
The verdict moves with mileage: the same car reads differently at 30,000 and at 150,000 miles.
What 2004 XC90 owners report, by mileage
Each system owners named in five or more complaints, with the mileage range where the middle half of those complaints were filed. Read at 78,000 miles.
| SYSTEM | COMPLAINTS | MIDDLE HALF FILED AT | TYPICAL US REPAIR BILLS |
|---|---|---|---|
| Electrical systemSTANDS OUT | 158 (34%) | 70k–116k miles · around this mileage | 12-volt battery replacement $100–$400 · Starter motor replacement $350–$1,200 |
| Transmission and drivetrainSTANDS OUT | 145 (31%) | 62k–107k miles · around this mileage | CV axle / CV joint replacement (one side) $300–$1,500 · Automatic transmission replacement $2,500–$7,000 |
| Fuel systemSTANDS OUT | 77 (17%) | 68k–140k miles · around this mileage | Fuel pump replacement $220–$1,500 · Fuel injector replacement (one injector) $300–$1,200 |
| Engine | 46 (10%) | 78k–122k miles · around this mileage | Valve cover gasket replacement $110–$500 · Timing chain replacement $1,000–$4,000 |
| Air bags | 31 (7%) | 66k–112k miles · around this mileage | — |
| Suspension | 23 (5%) | 40k–79k miles · around this mileage | Ball joint replacement (one joint) $200–$500 · Control arm replacement (one arm) $200–$900 |
| Steering | 20 (4%) | 18k–131k miles · around this mileage | Steering rack and pinion replacement $700–$2,100 |
| Brakes | 18 (4%) | 64k–120k miles · around this mileage | Brake pad replacement (one axle) $115–$390 · Brake pads and rotors replacement (one axle) $200–$1,084 |
| Speed control | 17 (4%) | 71k–133k miles · around this mileage | — |
| Exterior lighting | 32 (7%) | 88k–123k miles · ahead | — |
| Body structure | 14 (3%) | too few with a mileage | — |
| Stability control | 11 (2%) | too few with a mileage | — |
| Wheels | 10 (2%) | too few with a mileage | — |
| Equipment | 8 (2%) | too few with a mileage | — |
Bills are typical US ranges from the sources named in the tool (J.D. Power, Kelley Blue Book, CarParts.com and others), printed only for systems that stand out or sit at or ahead of 78,000 miles. Not a quote.
What owners reported alongside their complaints
Of 462 complaints: 9 mention a crash · 3 mention a fire · 7 report an injury · 1 says the car was towed.
No complaints in the last 12 months; the newest was filed in Mar 2025.
Counts of what owners wrote in their complaints, not verified by anyone.
In owners' own words
I drive a 2004 Volvo XC90 T6 awd. Suv. After 78,000 miles my transmission has completely failed without warning.
I was driving the vehicle and the transmission simply stopped propelling the car. It was as if it went into neutral while going 50 mph.
I have a 2004 Volvo XC90. At approximately 52k miles, the XC90 1st generation transmission went bad and had to be replaced.
Unedited excerpts from complaints filed with NHTSA, chosen by mileage (nearest 78,000 miles), not by content. Unverified.
Recalls for the 2004 Volvo XC90: 6
The batteries on those units may overheat. An overheated battery could lead to a fire.
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. 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.
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. The driver may notice that the vehicle is difficult to maneuver increasing the risk of a crash.
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. Inoperative wipers under inclement weather conditions could cause a crash due to impaired visibility.
On certain sport utility vehicles, the front wheel speed sensors may be defective, causing an erroneous wheel speed signal. 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.
On certain sport utility vehicles, the seat belt attachment(S) for the second and third row seat(S) may not have been fitted properly. In the event of a crash, the seat occupant may not be properly restrained, increasing the risk of injury.
A recall may cover only some cars of a model year; the campaign size counts every model and year it lists. Enter your VIN at nhtsa.gov/recalls: dealers fix open recalls free.
Service bulletins from Volvo: 137
Repair instructions Volvo sent its dealers for symptoms seen in the shop on the 2004 Volvo XC90. Ask a dealer or mechanic for a bulletin by its number.
On some vehicles, the software for transmission control module (TCM) fails to contain optimal calibration settings…
The 5 speed automatic transmission, AW55-50/51, has a bolt on top that anchors the B4 band, which applies 3rd gear
Retailers should only use a Volvo part number on claims for items purchased directly from Volvo
The Volvo Certified Pre-Owned (VCPO) warranty on all vehicles certified and retailed on or after 1/1/05…
NHTSA defect investigations: 3
Central Electronic Module Failure
Fuel pump leak
Windshield wiper arm performance
Neighbouring years
2003 XC90: 93 complaints, keep it, but watch the transmission · 2005 XC90: 223 complaints, keep it, but watch the engine.
Every Volvo XC90 year
2003 · 2004 · 2005 · 2006 · 2007 · 2008 · 2009 · 2010 · 2011 · 2012 · 2013 · 2014 · 2016 · 2017 · 2018 · 2019 · 2020 · 2021 · 2022 · 2023 · 2024 · 2025 · All XC90 years side by side
Other Volvo models: Volvo C70 · Volvo S40 · Volvo S60 · Volvo S70 · Volvo S80 · Volvo V70 · Volvo V70XC · Volvo XC40 · Volvo XC60 · Volvo XC70. All makes and models.
Questions
Is the 2004 Volvo XC90 a bad year?
462 owner complaints to NHTSA. Transmission complaints: 145, 15× a quiet XC90 year. At 78,000 miles the tool says: Consider selling. Half of all transmission complaints about the 2004 Volvo XC90 were filed between 62k and 107k miles. You're at 78,000 miles.
What are the most common problems with the 2004 Volvo XC90?
By owner complaints to NHTSA: electrical system (158), transmission and drivetrain (145), fuel system (77), engine (46), air bags (31). Half of the transmission complaints were filed between 62k–107k miles.
How many recalls does the 2004 Volvo XC90 have?
6 recall campaigns list this model year: Equipment (NHTSA 10V-566), Fuel system (NHTSA 09V-483), Steering (NHTSA 06V-155), Visibility and wipers (NHTSA 06V-144) and more. A recall may cover only some cars; check by VIN at nhtsa.gov/recalls.
Method: counts of unverified owner complaints filed with NHTSA, compared only with other years of the same model (sales volumes are unknown, so no failure rate is computed). A system stands out at 40+ complaints and at least twice the model's quiet (lower-quartile) year, or twice the share across every vehicle of that model year. The mileage range is the 25th to 75th percentile of the mileages owners reported. Data received by NHTSA through November 5, 2026. Repair prices are typical US ranges from named sources, not quotes. Not a diagnosis and not financial advice. PulsCar is not affiliated with NHTSA. Check this car at your own mileage.