2004 Volvo XC90 Volvo XC90 2004

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2004 Volvo XC90 repairs by problem area

Engine (31%)

Transmission and Drivetrain (15%)

Brakes and Traction Control (6%)

Suspension and Steering (21%)

Electrical and Air Conditioning (17%)

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

Other (4%)

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Chart based on 277 repairs.
See TSBs and recalls for the 2004 Volvo XC90.

2004 Volvo XC90 transmission repair cost distribution

$2500+ (20%)

$1000 - $2499 (23%)

$500 - $999 (13%)

$100 - $499 (15%)

< $100 (30%)

Chart based on 40 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

86000 mi

US $1500
Transmission went, stuck in third gear. 
71300 mi

Replaced the solenoid and master kit of transmission. Fault codes: TCM-002B 4th gear. Incorrect gear ratio. TCM-000B Shift solenoid S1. Hydraulic fault. BCM-0115 Communication between control modules. BCM-0103 Pedal position sensor. Faulty signal.  
86000 mi

US $800
Had to replace front right axle. 

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2004 Volvo XC90 4dr SUV

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

130200 mi

Gear Box Serviced Prop Shaft replaced Head Gasket Serviced Aircon Radiator Replaced Radiator Replaced 
128000 mi Main drive shaft was clicking, starting to fail 
84000 mi Transmission services light was on. Dealer installed software, which made light go off. Because of this, I did not have transmission further inspected. 
138000 mi

US $160
Front bearing boot at driveshkaft connection to rear was completely worn and no grease inside; car made metal clicking sound on acceleration and deceleration; prop shaft may need replaced eventually 
97200 mi

US $1500
Volvo warrantied a complete new transmission and cooling lines and radiator 
140700 mi

US $800
replaced rear drive shaft 
75200 mi at 75K miles the 'transmission service urgent' warning light came on. The Volvo dealership diagnosed a faulty transmission that needed total replacement--evidently this is a known issue which is why Volvo paid for the replacement. 
47000 mi

US $241
Transmission developed a significant bearing noise  
60800 mi

US $60
Transmission Output shaft seal was leaking, according to TSB and repair history was likely caused by the dealers replacement of the transmission. 
70000 mi

US $125
Leaking seal replaced 
93000 mi

US $5200
"Service Transmission Urgent" light came on, had been having no problems but all of a sudden seemed to be starting in 2nd gear and not shifting into first. Dealer said I need a new transmission, total cost, $5200.00 
141000 mi

US $874
Bad left front Axle. 
106000 mi

US $1800
Car had been doing a light whistling noise under moderate acceleration usually between 5 and 20 MPH. Then transmission alert came on. After restart, transmission worked fine. Took to transmission specialist. Replaced all wearable for $1,800. 
160000 mi

US $5000
failed transmission again. This is the second time 80k miles apart. 
64000 mi awd didn’t work at all – probably electronic problem, costs ~ 2000$ to fix, dealer said whole rear differential needed changing ~ $4500 
60140 mi Transmission require urgent message incidator appeared. 
80000 mi The transmission was rebuild and fully paid for by Volvo under Goodwill agreement. 
39000 mi Replaced entire drivetrain. Took 5 months for parts to be shipped and clear customs. 

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2004 Volvo XC90 4dr SUV

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

134000 mi

US $1900
All wheel drive broke 
520000 mi

US $4200
repair/replace transmission 

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2004 Volvo XC90 4dr SUV

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

90000 mi under warranty, replace transmission 
106000 mi

US $4000
replace front differential after major breakdown. Replaced under courtesy warranty chain box 
112840 mi Haldex DEM PCB burned beyond repair due to water ingress (poor sealing) 
130000 mi Driveshaft making noise and needed replacement ($1900.00). Since tranny replaced twice (Volvo paid for total repair 1st time and 2nd time and I paid for labor at $2200.00) decided enough was enough and traded it. 
110000 mi

US $35
Replaced shifter knob button with an upgraded part from ebay 
88000 mi

US $980
Vibration upon acceleration. Replaced right front axle. Is an apparent problem with this vehicle. 
59380 mi

C $3300
Part that comes off the transmission that runs the rear wheels was leaking oil and making noise. Was replaced due to being worn out. 
72000 mi In this trip our XC90 received a new transmission and angle/bevel gear. 
70000 mi

US $220
Reseal angle gear 
72000 mi

US $380
According to the dealer, there is a design problem with the transmission in the 2004 Volvo XC90. They "commonly fail" somewhere around 70K miles. Took them a week to replace the non-working transmission with a "refurbished" one. 
147700 mi

US $1400
Rebuild differential control module and replace anti-skid module. 
82000 mi

US $500
AWD not working (DEM and spline sleeve issue) 
127000 mi

US $4000
replaced front axle 
132000 mi

US $150
Worn axle 
54000 mi

US $1000
Leak at transmission 

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2004 Volvo XC90 4-door

turbocharged 5-cylinder diesel automated manual AWD

73500 mi

Rear wheel drive sleeve stripped common problem 
76000 mi

Gearbox had problem again of Transmission service required on dashboard as this is now third time decided to go for complete gearbox replacement told by service staff they had done a lot of gearbox changes recently. 

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2004 Volvo XC90 4-door

5-cylinder automatic AWD

140000 mi

US $2487
Replace 2 front axels, 

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See TrueDelta's information for all Volvo models.

2004 Volvo XC90 Transmission Problems

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