Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: The XC90 took its “freshman 15” of transmission complaints and turned it into a “sophomore 45.” The 2004 XC90 saw 3X as many complaints about the transmission failing as it did in its inaugural North American model year! By the following year, transmission complaints fell back in line with the 2003. That sharp spike in complaints means we recommend avoiding the 2004.

On top of transmission complaints, the 2004 XC90 also has problems with a sudden loss of power. The lucky ones are met with a “reduced engine performance” message, while others are left stranded on the side of the road waiting for a tow.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
53,893 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Volvo XC90 fuel system problems

fuel system problem

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2004 Volvo XC90 Owner Comments

problem #7

May 152016


  • 132,000 miles


The contact owns a 2004 Volvo XC90. While driving, there was a strong odor of fuel in the vehicle. The contact noticed fuel leaking onto the ground. The vehicle was taken to a dealer where it was diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The vehicle was not included in NHTSA campaign number: 09V483000 (fuel system). The failure mileage was 132,000.

- Clinton, NC, USA

problem #6

Oct 292008

XC90 5-cyl

  • miles
Recall 2004 Volvo XC90 fuel pump the consumer stated she experienced the problem back in October 2008. There was a horrible gas smell coming from the vehicle. The dealer was unable to diagnose the problem the first time. The consumer is seeking reimbursement.

- Boca Raton, FL, USA

problem #5

Nov 132009


  • 50,000 miles
The contact owns a 2004 Volvo XC90. She smelled a strong odor of gasoline coming from her vehicle while parked. The vehicle was taken to the dealer for inspection. The technician stated that the fuel pump needed to be replaced at an expense of $1200. The failure mileage 50,000. The vehicle identification number was unavailable.

- Austin, TX, USA

problem #4

Sep 172009


  • 75,000 miles


The contact owns a 2004 Volvo XC90. The contact smelled fuel in the vehicle and observed that there was a leak in the fuel tank. The mechanic confirmed that the fuel pump gasket caused the failure. The manufacturer advised her to contact the dealer and offered to pay for the repair minus the service charge. The vehicle has not been repaired. The current mileage was approximately 78,000. The failure mileage was approximately 75,000.

- Santa Monica, CA, USA

problem #3

Sep 252009


  • 40,000 miles
The contact owns a 2004 Volvo XC90. The contact smelled a strong odor of fuel outside of the parked vehicle and inside of the vehicle while driving. The failure occurrence was intermittent and has progressed. An authorized dealer stated that the failure was contributed to a cracked fuel pump housing. The vehicle has not been repaired. The contact was extremely concerned about the safety hazard. The failure and current mileage was 40,000. Updated 10/21/09. Updated 10/20/09

- Miami, FL, USA

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problem #2

Nov 112008


  • 24,000 miles
Faulty fuel pump, broker fitting on inlet, leaks gas.

- Henderson, NV, USA

problem #1

Sep 052007

XC90 5-cyl

  • Automatic transmission
  • 56,252 miles
While the car was parked in the garage there was an overwhelming smell of gasoline. I took the car to my mechanic. They observed a fuel leak coming from fuel pump housing. A new fuel pump was installed.

- Phoenix, AZ, USA

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