Which parts fail
Components named in complaints (headlights, tail lights, turn signals, interior lights).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Volvo XC90 owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
Hello Volvo, for the record, we love our Volvo SUV (2004, XC90). Over the years the service from michelle balside at Volvo on plainfield road in cincinnati has been truly excellent, her contact information is attached. However, we have has an issue since 2011 that has not been resolved, which is so uncharacteristic of Volvo. I am hoping you can help me change the outcome. For years my husbands right headlight has been turning on and off intermittently. This is very dangerous when he drives to and from work at night on an old 4 lane highway (columbia parkway) that has no separation between east and west bound lanes, which means cars travel head-on at 70 miles an hour. Our dealer looked at the issue several times and said they could not fix it; so we lived with the dangerous issue because we thought the problem was unique to us. …
I had this problem a few times a year ago and now it has returned. I was driving my car at night in the rain on a two lane freeway when all of a sudden I lost the headlights, dash lights, speedometer, radio, power windows, electric transmission, and much more function of the car. The engine is still running but it seems to almost reset or something then start shutting stuff down. I see on your website someone put this in as a complaint also this is very dangerous you cant see at night the car is hard to drive its obviously this same problem with water getting into the ECM. I read through your information and it seems like Volvo knew something was up with ones produced before or after March. It seems like they have been well aware of the problem and still want to charge you $2000 to fix it! …
Similar to many others, while driving our 2004 Volvo XC90, we hear a click, then the climate, radio and windshield wipers (if on) shut off and their display lights black out, then another click in a fraction of a second and they come back on. This was happening randomly, and nothing else was affected, until this weekend, while on a trip. We were driving on highways, outside temp in the 80's, no rain, average speed about 70mph. It happened a few times over about 45 minutes, then began happening every 5 miles or so. When I turned up the ac fan, within about a minute it clicked and we lost the usual things, but they did not come back on. …
I switched from headlights on to daylight driving lights on. I received a "bulb failure" for the daylight driving lights. I switched back to headlights. I received a "bulb failure" for the hids. I have verified that the fuses are good, and that there are now no working headlights on the car. Had this happened at night it could have been bad, very bad. Thank god it happened during a sunny day and that the teen driver wasn't behind the wheel.
After driving 125 miles without incident, we left our 2004 Volvo xc 90 t6 AWD parked for 4 hours before driving again. After less than a half mile at low speed, there was a "thump" from the front of the car, the wipers cycled, the gauges all went blank, some of the windows stopped working, the A/C went out (blower stayed on). The car stayed on, but seemed "stuck" in second gear and the brakes became "spongy," but operable. Turn signals were inoperable and the power steering went out. The indicator light on the gear shift went out and the central locking system stopped functioning. We got out of traffic and into the shade. I checked all fuses and tried to restart the car. It would restart, but within seconds there were multiple "clicks" coming from the area near the fuse box in the passenger compartment followed by the electrical failures described above. …
This has to do with faulty headlight system on this car. I have had repeated failures of the low beam on both sides. The connector that the headlight plugs into overheats to the point where the plastic connector melts and no longer works. To fix it requires that a new connector be purchased and spliced in to replace defective part. It appears that the wire gauge is too low thus creating both a fire hazard as well as a safety hazard from having head lamps fail. I have spoken to both my local dealership and Volvo corporate about this problem and they both say that there is no recall thus there is nothing they can do to help fix it at their cost. Of course, they are more than happy to have me pay them a ridiculous price to repair it for me. They seems to care not that this is a safety issue. …
2004 Volvo XC90 sudden engine stall with lose of headlights: I was traveling on the interstate at night with the cruise set at 75 MPH when suddenly it was like someone turned the ignition key to off for about 3 seconds, and then turned the key back on without restarting the engine. With all the warning lamps illuminated, and the engine at a stall I pulled into the emergency lane, and stopped. I then shifted to park and attempted to start the vehicle, where it took several attempts to start. The headlights did not stop working while pulling over, and when I stopped I switched the lights off before I restarted the engine. The first thing at mind was a fuel pump that was starting to act up. After restarting I revved the engine up a few quick times (to clear the engines throat). I then got back on the interstate accelerating to 75 MPH , but doing so manually this time(no cruise control). …
Unsafe front suspension repaired 4 times by Volvo involving district factory technical supervisor and technicians on 3 of four occasions and the vehicle still has serious safety and handling concerns - no one in the family will drive the car. It has also had serious performance related safety issues regarding vehicle electronics virtually shutting the vehicle down in the middle of an interstate. Anti skid problems on multiple occasions. Drivers seat belt anchor was improperly attached and would not have held in an accident. The steering wheel came dangerously loose while driving and the dealership stated that it had never been properly affixed. (I have owned 300 cars in my life and never has a steering wheel come loose)! Tires were abnormally badly and quickly due to significant suspension problems and were not warranty by the manufacture.. …
My headlights, driving lights, park lights, and turn signals are not working. This began when I started to go somewhere last night. All of these things were working the day before. The tail lights, turn signals, and brake lights are working in the rear. My vehicle is garaged when it is not in use. My radio, cd player, or satellite radio would not operate 2 days ago and started working the next time I started my car. About 2 weeks ago the car wouldn't start. It acted like the security system had been activated as it would crank, but not start. I waited for about an hour and tried it again and it started the first time. I have checked all fuses. I am taking it to the repair shop today to see if they can figure out what is happening. These problems are intermittent and do not repeat often enough to diagnose properly. …
Headlight complaints in other XC90 years
Frequently asked questions
How common are headlight problems on the 2004 Volvo XC90?
NHTSA has 33 complaints about the lights of the 2004 Volvo XC90, 7% of the model year's 462 complaints. The component named most often is headlights (2 mentions).
Is there a recall for 2004 Volvo XC90 headlight problems?
No. NHTSA lists no lights recall for the 2004 Volvo XC90, though it has 6 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Volvo XC90 headlight problems start?
Half of the complaints with a recorded mileage happened before about 105,000 miles, and 3% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.