Which parts fail
Components named in complaints (automatic and manual transmissions, CVT, axles, driveshaft, 4WD/AWD).
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).
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 am concerned these 2 issues May pose a safety risk. I recently purchased this car from a friend and have had it about a month. I notice the steering is very stiff and difficult to maneuver. I was trying to find out if there were any recalls on this but having no luck. Also, when the car is in gear "drive", when stopped on an incline (even the slightest hill) I notice that when I take my foot off the brake pedal the car rolls backwards! It shouldn't do that. The transmission notice on the dash is saying it needs service but my friend I bought it from said she had it checked twice and was told there is no transmission issue. Is there a recall on power-train/trans parts? The car should not roll backwards when in gear "drive", even if I am stopped on a hill. Even a slight incline and the car rolls back. Not normal. Thank you for any and all help you can offer. …
When I brought my car to ramsey Volvo for service, Volvo recommended the angle gear reseal service because the angle gear box is leaking as shown in the attached picture. Upon further research, I found that this is a very common issue with all Volvo xc90s, so much so that it can be classified as a manufacturer defect, and qualifies as a recall in my opinion. The angle gear box is an undisturbed part and is supposed to be sealed for the lifetime of the car. When the fluid in the angle gear box is completely leaked out, which is something with no indication whatsoever, the car would lose all wheel drive according to Volvo. When that happens in a slippery situation with ice or snow, the car is most likely to lose control and would lead to a serious accident with potential loss of lives. …
Tl* the contact owns a 2004 Volvo XC90. The contact stated that while the vehicle was being driven, the transmission failed to shift out of third gear. The contact was also alerted to a message display which indicated a transmission failure. Additionally, the vehicle would independently shift to neutral. Niello Volvo cars sacramento located at 4609 madison ave, sacramento, ca 95841, [phone]), was contacted by phone. The contact inquired about NHTSA campaign number: 03V434000 (wheels). The contact was informed that the vehicle was not included in the recall. The vehicle was towed back to the residence. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 125,000.
Bought the vehicle with 112,000 miles on it, it has a gas leak trickling down the side of the gas tank, probably a bad sending unit, fumes are bad some days but worse on warmer days. The transmission failed one day with no warning or light, it just lost momentum and failed to engage in drive. I think this is due to the poor engineering design Volvo used. This model is the t6 with the GM 4t65e transmission which is widely known to fail even at low miles. I think a full safety recall should e sanctioned for all model years with these horrible problems
The Volvo has constant issues when shifting and getting stuck in a specific gear. Also it will decide to down shift out of know where. I can be doing 55 on the highway then it slams into 3rd and I lose control of the vehicle almost making me crash. Mechanics do not see anything weong with the transmission ie its going bad but something is making the vehicle do this. Software possibly TCM not working properly but my mechanic also insepected that. After much research it seems to be a very well known and unsafe condition.
While I'm motion the SRS airbag light came on transmission urgent light came on and ABS light the battery keeps bubbling like its gone blow up in my trunk I have to jump it off every morning I paid alot for this SUV can you please help me keep my only car in working order I have had all maintains done in past now the coolant system is leaking what is going on with this Volvo XC90 t6 AWD [redacted] '
Tl* the contact owns a 2004 Volvo XC90. The contact stated that the all wheel drive sensor malfunctioned. The vehicle was taken to a mechanic, but was unable to be diagnosed or repaired. The manufacturer was not aware of the failure. The vehicle was not included in NHTSA campaign number: 03V434000 (wheels). The contact stated that the vehicle experienced the same failure listed in the recall. The failure mileage was 172,000.
Tl* the contact owns a 2004 Volvo XC90. The contact stated that while driving at an unknown speed, the vehicle stopped independently. The vehicle was towed to an independent mechanic where it was diagnosed that the tie rod needed to be replaced. The vehicle was repaired but the failure recurred. The manufacturer was not made aware of the failure. The approximate failure mileage was 150,000.
Tl* the contact owns a 2004 Volvo XC90. While driving at any speed, the vehicle jerked and lost power. The contact also heard water running on the right passenger side door and underneath the dashboard. The air bag warning light illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 113,00. The VIN was not provided.
Transmission complaints in other XC90 years
Frequently asked questions
How common are transmission problems on the 2004 Volvo XC90?
NHTSA has 145 complaints about the transmission & drivetrain of the 2004 Volvo XC90, 31% of the model year's 462 complaints. The component named most often is automatic transmission (102 mentions).
Is there a recall for 2004 Volvo XC90 transmission problems?
No. NHTSA lists no transmission & drivetrain 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 transmission problems start?
Half of the complaints with a recorded mileage happened before about 78,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to transmission & drivetrain problems on this model year. If you notice symptoms, have the car checked before driving further.
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.