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:
51,183 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 suspension problems

suspension problem

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2004 Volvo XC90 Owner Comments

problem #5

Oct 032007

XC90 6-cyl

  • Automatic transmission
  • 56,015 miles


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.

- Monroe, MI, USA

problem #4

May 012007

XC90 6-cyl

  • Automatic transmission
  • 34,500 miles
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.

- Westborough, MA, USA

problem #3

Jul 072006

XC90 4-cyl

  • Automatic transmission
  • 40,000 miles
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 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.

- Westford, MA, USA

problem #2

Jun 152007

XC90 4WD 5-cyl

  • Automatic transmission
  • 70,000 miles
The contact owns a 2004 Volvo XC90. The contact heard a noise while driving 25-30 mph. There were no warning indicators. The rear bearing axle was replaced. The tumbler ignition lock failed and the key could not be removed. The vehicle was towed and the ignition lock was replaced. The VIN, purchase date, and engine size were unknown. The current mileage is 74,000 and failure mileage was 70,000. Updated 02-01-08 updated 02/01/08

- Barnegat, NJ, USA

problem #1

Apr 242007

XC90 4WD 6-cyl

  • Automatic transmission
  • 55,400 miles
Wheel bearings have been replaced twice under warranty. The problem has recurred. This part needs to be recalled.

- Macedonia, OH, USA

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