Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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).
I keep getting that the anti-skid needs to be serviced but when I got it checked they reported that they couldnt find anything wrong with the anti-skid and the error is constantly lit in the service window of the vehicle. I can feel the difference while driving in wet conditions. Is there anything specific they should look for other than advising me that its probably a sensor. I don't feel safe driving in rain.
Tl* the contact owns a 2004 Volvo XC90. The contact stated that while driving approximately 15 MPH, the front end of the vehicle independently traveled out of lane. In addition, the anti skid warning light illuminated. The failure recurred continuously. The vehicle had not been diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 98,000. Kmj
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.. …
Transmission replaced June 08 front control arms and bushings and coolant reservoir replaced sept. 08 thermostat & housing & temp sensor replaced jan. 08 brake vacuum pump replaced for 2nd time jan. 08 brake vacuum pump replaced sept. 07 gasket, o-ring, hose clamp recall sept. 07 power steering pump and brake vacuum pump installed July 07 steering rack solenoid replaced July 07 - (recall May 3, 08?) new Bridgestone tires May 07 upper engine torques mount replaced March 07 recall wiper arm 156, ball joint 157 oct. 06 brake pad & rotors replaced oct 06 upgrade software a & c July 05 ABS brakes warranty fix May 06 front pads & rear pads & rotors replaced dec. 05 exhaust rubbing on driveline, install kit to hold exhaust off driveline dec. …
Rear hub (bearings) on passenger side failed. This is the third time a rear hub failed. The first time in 2005 the vehicle had 28,000 miles. This time the rear wheel was held on by the brake caliper according to the Volvo dealer that rebuilt it. The second was the driver side rear hub failed in 2007 with 72,000 miles. The third was the passenger side rear hub that failed about a week ago. The vehicle mileage was 84,000. This vehicle is maintained according to the manufacturer's schedule. It is quite dangerous (refer to the first incident). There needs to be a recall would seem to be the correct outcome. Though there is an extended warranty after the 50,000 mile period there has been a cost to us.
Wheel bearing failure. Volvo XC90 put an SUV ontop of a car chassis causing too much load on wheels and wheel bearing. Tires wear out often and bearings need to be replaced repeatedly. If you search forums like:http://townhalltalk.edmunds.com/direct/view/.f0ed3f5/0 http://forums.swedespeed.com/zerothread?id=77305 http://www.Volvo-forums.com/t7392-reliability-concerns-about-2006-XC90.htm you will see that many car owners have this same problems. Volvo need to let customers know that this is a problem. This is dangerous and can cause serious injury. Instead of keeping it hush they should inform consumers and do a recall.
Transmission replaced two times, at approx. 38,000 and at about 48,000 miles. Units start slipping when shifting to second gear and leave you right where you are until they decide to rengage. Ball joints and all four hubs replaced by 50,000 miles. Axles (front) need replacing now at 70,000 miles. Sway bar ends replaced at 55,000 miles. This is the neediest vehicle I have ever owned. Front bearings on drive shaft replaced last month, worn since abut fifteen thousand miles, finally got so loud that we could shake the drive shaft and get a quarter of play at the bearing set.
The front end tie rod broke suddenly on our 2004 Volvo XC90 bringing the car to a complete halt just after my son had pulled on to the exit ramp after driving 35 miles on a major 6 lane highway in new jersey. We were soooo lucky. Volvo replaced both front end tie rods with what they claim to be a new and improved tie rod. We still question the safety of the car at this point and will not allow our teenagers to drive it on the highway. Volvo USA has been antagonistic with us about taking back the car but our local dealer is willing to trade it for another Volvo.
I have now experienced the failure of the second rear wheel bearing on my 2004 Volvo xc-90 AWD, with the second failure resulting in the partial separation of the wheel from the vehicle at highway speeds. There is a defect in the design of the wheel bearing, and these bearings should be replaced in the field before ther is a fatality or serious injury. Although Volvo has replaced both bearings under warranty, a brief internet search indicates this is a very common failure on this model. Damage on the second failure resulted in $1800 damage to the vehicle.
I have my 2004 XC90 t6. At about 34K miles a noticeable 'thrum' began somewhere in the drivetrain. Original diagnosis was worn tires. After replacing tires, the noise has become worse. Now at 35K miles is very loud. New diagnosis is failing wheel bearing. A bit of research indicates I am not the only XC90 owner with a wheel bearing failure. Wheel bearing failures at 35K miles this should be declares a defect and recalled. Please research this problem.
Suspension complaints in other XC90 years
Frequently asked questions
How common are suspension problems on the 2004 Volvo XC90?
NHTSA has 23 complaints about the suspension of the 2004 Volvo XC90, 5% of the model year's 462 complaints. The component named most often is rear (7 mentions).
Is there a recall for 2004 Volvo XC90 suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 67,000 miles, and 14% 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.