2004 Volvo XC90 Volvo XC90 2004

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2004 Volvo XC90 repairs by problem area

Engine (32%)

Transmission and Drivetrain (15%)

Brakes and Traction Control (6%)

Suspension and Steering (20%)

Electrical and Air Conditioning (18%)

Paint, Rust, Leaks, Rattles, and Trim (5%)

Other (4%)

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Chart based on 282 repairs.
See TSBs and recalls for the 2004 Volvo XC90.

2004 Volvo XC90 suspension repair cost distribution

$2500+ (4%)

$1000 - $2499 (19%)

$500 - $999 (21%)

$100 - $499 (32%)

< $100 (25%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 53 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2004 Volvo XC90

Engine not specified

85000 mi Cracked and broken Front Lower Control Arms, front and rear bushings. Sold instead of repairing. 
93000 mi

US $480
wheel brearing replaced - rear driver's side 
109000 mi

US $287
front sway bars replaced 
220000 mi

US $900
Replace front bushings 

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2004 Volvo XC90 4dr SUV

turbocharged 268hp 2.9L I6 4-speed shiftable automatic AWD

162000 mi Powersteering pump bleed-screw leak 
70000 mi

US $1200
Car has been veering slightly to left when braking. Problem got progressively worse. Rear left control arm bushing was shot, right was badly worn. Both were replaced. I think actual control arm was replaced too (?) Problem fixed but pricey. 
133000 mi steering fluid leak due to hose connection was aged. 
129000 mi

US $2261
Front strut sprngs found brokn: both spring seats replaced. Power steering hose leak. Needs lower control arms, rear sway bar links, tie rods, steering column u-joint. 
137900 mi

US $4300
needed complete front end repair kit leaking steering hose 
147300 mi

US $435
Loose stabilizer bar 
70961 mi

US $865
Replaced leaking power steering pump Replaced leaking power steering pump 
78000 mi

US $940
Power steering pump replaced again due to leaking seals. 
75200 mi there was a gear broken in the steering column during the transmission removal. Volvo says it wasn't their fault, but that they consistently see this problem when transmissions fail. Volvo says it's unrelated to the transmission failure. 
62000 mi

US $358
The tie rod was replace also and oil change and have sun roof leak taken care of. 
47120 mi

C $700
failed endlinks 
141000 mi

US $874
Bad tie rods 
199000 mi

US $130
This great yet aged car is giving some feedback when I brake, a little move in the steering wheel, with having to turn my steering wheel a bit to the right while stopping. Paid for diagnosis. Worn suspension rubbers and lower control arm bushings 
201000 mi

US $750
Front bushings badly worn out with impact during braking. Replace lower control arms on both sides, with new bushings of course. Then 4-wheel alignment. Pb fixed 
46000 mi Replaced 2 wheel bearings. Seal on Fuel Tank was broken during wheel bearing repair. Terribly strong smell of leaking fuel. Car not driveable. Dealer repaired under factory warranty w/o admitting fault. 
49000 mi Replaced a third wheel bearing. 
65000 mi

US $1100
Car made a clunking sound in the front driver's side while turning or backing up. Dealer replaced the control arm brushings and upper engine mount. 
88000 mi

US $500
Dealer found part of the suspension system needed to be replaced and gave a quote of $900 to repair. 
60800 mi

US $60
Roll bar links failed, replaced both sides with OEM new 
142300 mi

US $350
Inner and Outer Tie rods replaced Driver and passenger side ball joints replaced. Further reduced how often the suspension makes a loud popping clunk noise when turning to the lock either way at low speeds. Still makes it sometimes. 
152000 mi

US $75
Front left wheel bearing was making noise new bearing didn’t solve issue 

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2004 Volvo XC90 4dr SUV

turbocharged 208hp 2.5L I5 5-speed shiftable automatic FWD

134000 mi

US $1800
Replace sway bars, fix front suspension,  
141000 mi

US $275
When replacing the struts of front wheels, it was found that the tie-rod was broken and required replacement 
174000 mi

US $346
Lower ball joints of both front worn out. 
93000 mi

US $100
Right rear bearing replaced under extended warranty 
123000 mi

US $600
Had left rear wheel bearing changed 

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2004 Volvo XC90 4dr SUV

turbocharged 208hp 2.5L I5 5-speed shiftable automatic AWD

99200 mi

$300
Rear wheel bearing hub noise. Replaced hub. 
16000 mi steering rack replaced 
45001 mi both rear wheel bearings replaced 
115300 mi

US $1556
Heavy rubbing sound whenever making a turn. Had to replace steering shaft boot and adjust steering shaft. 
157000 mi

US $1600
Multiple front end repairs completed, tie rod ends, sway bar, bushings. The symptoms involved sharp veering to the left upon sudden braking. An unknown problem remains, the vehicle needs tires every 20,000 miles. 
182000 mi

US $125
Replaced right rear wheel hub due to noisy bearing. 
187000 mi Replace left rear wheel hub. 
199000 mi

US $650
End joints replaced, $300 
210000 mi

US $1370
Replace left front spring seat 
40300 mi Rubber bushings for front sway bars replaced 
88000 mi

US $980
Replaced sway bar and bushings. 
90000 mi

US $478
Replaced worn (noisy) right rear wheel bearing. It may not be common to all cars, but it apparently is a problem for Volvo XC90's and, though it may be coincidental, my 2003 Chrysler minivan too. 
70000 mi

US $220
Replaced Lateral Link 
94000 mi

US $100
Sway bar end link dampers replaced. 
121000 mi

US $800
rear suspension bushings 
112000 mi

US $2000
replaced ball joint on driver side front suspension 
127000 mi

US $4000
replaced struts 
54000 mi

US $1000
Front bushings about to fail. Noticed when tires were replaced at tire shop (not dealer) Steering control arms replaced 
77000 mi

US $150
In for routine maintenance, while testing, found the rack and pinion steering had to be replaced. We have the extended warrantee and were told that it would have cost about $7000 but was covered under the warrantee. 

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2004 Volvo XC90 4dr SUV

turbocharged 161hp 2.4L I5 Diesel 5-speed shiftable automatic AWD

84000 mi

£200
PAS stopped working properly. Pump removed checked & cleaned. System flushed & fluid replaced. 
86500 mi

£400
Replaced all four wheel bearings due to moaning noise when driving - some of this was preventative as just about to embark on 2,000 mile holiday drive. 

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2004 Volvo XC90 4-door

5-cylinder automatic AWD

140000 mi

US $2487
2 front wheel hub assembly, 

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2004 Volvo XC90 Suspension Problems

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2004 Volvo XC90 problems occur, check out our car reliability stats.