RoadVitals

2003 Volvo XC90

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
93
Latest Jun 20, 2022
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
5
Latest Nov 8, 2010
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
4
6 injuries, 0 deaths reported

Overview

Our database contains 93 NHTSA owner-reported complaints for the 2003 Volvo XC90, most frequently naming the transmission, electrical and fuel system categories. 5 safety recalls have been issued covering this model year; and 239 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

5 campaigns cover this model year

View all 5

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
10V566000

EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

Nov 8, 2010
416 units potentially affected
The defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
The risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
The remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
VOLVO CARS OF N.A. LLC.Manufacturer number R231View on NHTSA.gov
09V483000

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Dec 18, 2009
158,733 units potentially affected
The defect: VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATE AND TEMPERATURE CYCLING) OVER TIME AND IN COMBINATION WITH VARYING FUEL QUALITY, THE FUEL PUMP CAN DEVELOP CRACKS IN THE FUEL PUMP FLANGE.
The risk: IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
The remedy: DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
VOLVO CARS OF N.A. LLC.Manufacturer number R220View on NHTSA.gov
06V155000

STEERING:LINKAGES:TIE ROD ASSEMBLY

May 5, 2006
126,743 units potentially affected
The defect: ON CERTAIN PASSENGER VEHICLES,THE OUTER TIE ROD BALL JOINT CAN DEFORM AT HIGH LOADS CAUSING A LOSS OF THE CLAMPING FORCE AND THE NUT MAY LOOSEN, WHICH MAY EVENTUALLY LEAD TO A FATIGUE FRACTURE OF THE OUTER TIE ROD BALL JOINT.
The risk: THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.
The remedy: DEALERS WILL REPLACE THE OUTER BALL JOINT TIE RODS WITH IMPROVED OUTER BALL JOINT TIE RODS FREE OF CHARGE. THE RECALL BEGAN ON JUNE 23, 2006. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
VOLVO CARS OF N.A. LLC.Manufacturer number R157View on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

View all 93
Fuel system
Filed Jun 20, 2022

Fuel line was recalled in 2010. Volvo repaired it now it has the same problem. And is leaking fuel. Same line that they replaced in 2010. Please recall.

NHTSA ID
11470083
Incident
Jun 20, 2022
Powertrain (other)
Filed Feb 2, 2021

TRANSFER CASE KEEPS LOCKING UP AND MESSING UP. IN PAST YEAR PAID 1500 TWO TIMES TO REPLACE TRANSFER CASE AND IS NOW IN SHOP AGAIN FOR SAME REASON. TRANSFER CASE LOCKING UP. FEB 2020, JULY 2020, AND NOW JANUARY 2021 FEB GOING SPEED OF 35-40, JULY ON HIGHWAY SPEED OF 70 IN MIDDLE OF FREEWAY, AND JAN SPEED OF 35

NHTSA ID
11394283
Incident
Jan 29, 2021
Mileage
141,000 mi
Driver assistanceElectricalEngine
Filed Dec 15, 2015

DRIVING THE XC90 AND SUDDENLY THERE IS A HUGE THUMP AND CLICKING FROM THE DASHBOARD. ALL THE DIALS AROUND THE SPEDOMETER STOP WORKING.. IF WE KEEP DRIVING THERE ARE MORE THUMPS AND WE QUICKLY LOSE ENGINE POWER - IT IS EXTREMELY SCARY WHEN IT HAPPENS.. ALL THE LIGHTS COME ON (INSIDE THE CAR), DASHBOARD GOES DEAD ETC ETC. IT IS EXTREMELY DANGEROUS .. IT HAPPENED TO USE A NUMBER OF TIMES WITH 3 CHILDREN IN THE CAR. IT HAS OCCURRED WHEN WE WERE DRIVING ON THE HIGHWAY, 2-3 TIMES, IT HAS OCCURRED ON SHORT TRIPS - IT HAPPENS AT SEEMINGLY RANDOM TIMES, USUALLY AFTER DRIVING FOR OVER 30 MINUTES, BUT THEN YESTERDAY IT HAPPENED ON A TRIP JUST DOWN TO THE PARK, NOT 5 MINUTES DOWN THE ROAD.. ON THIS OCCASION THE CAR HAD BEEN SITTING IN THE SUN FOR A WHILE (MAYBE HEAT RELATED?). IT HAS HAPPENED IN HOT WEATHER, COLD WEATHER .. WE ARE IN CONSTANT FEAR WHEN DRIVING THE CAR. I HAVE CONTACTED VOLVO AUSTRALIA ABOUT THE ISSUE BUT THEY SAID THEY HAVE NO RESPONSIBILITY, THAT THERE IS NO RECALL FOR THE PROBLEM AND DIDN'T WANT TO HELP AT ALL!! I SEE A LOT OF PEOPLE HAVE THIS SAME PROBLEM, IS VOLVO NOT GOING TO FIX IT UNTIL SOMEONE IS KILLED??? WHAT WILL IT TAKE!?!?!?! IT IS A JOKE ! WE BOUGHT A VOLVO TO HAVE SOMETHING SAFER THAN NORMAL BUT ITS MORE DANGEROUS! I CANNOT EVEN SELL THE CAR BECAUSE I DON'T KNOW WHAT'S WRONG WITH IT AND I DON'T WANT ANOTHER FAMILY / PERSON TO BE INJURED .. NO RESALE VALUE, NO SAFETY! COME ON VOLVO, THIS IS CRAZY!

NHTSA ID
10810354
Incident
Dec 15, 2015
Mileage
230,000 mi
EnginePowertrain (other)
Filed Aug 31, 2015

WHEN THIS VEHICLE WAS PURCHASED IT STARTED WITHIN 4 DAYS TO HAVE PROBLEMS WITH THE TRANSMISSION, AFTER THE TRANSMISSION THE TRANSFER CASE BEGAN TO HAVE PROBLEMS, SO THE VEHICLE WAS PLACED IN THE SHOP BEFORE THE THIRTY DAYS TAGS COULD EXPIRE AND BOTH PARTS WERE REBUILT BY AN OUTSIDE COMPANY WHICH WAS ADDED TO THE ORIGINAL PRICE TAG OF THE VEHICLE. THEN A YEAR LATER THE VEHICLE WAS PLACED IN THE SHOP FOR THE TURBO'S HAD GONE OUT ON THE VEHICLE ON APRIL 11, 2015 UNTIL CURRENT DATE. THEY ARE NOW SAYING THE VEHICLE HAS A BLOWN HEAD GASKET AND IT IS STILL IN THE SHOP.

NHTSA ID
10760442
Incident
Apr 10, 2014
Mileage
114,687 mi
Body & structureElectrical
Filed Aug 19, 2015

VEHICLE DRAINS WATER ON TO FRONT PASSENGER FLOOR, AND OCASSIONAL DRIVER SIDE AFTER IT RAINS. IT IS A KNOW PROBLEM THAT A CLASS ACTION SUIT WAS WON IN NEW JERSEY, INCLUDING 5 OTHER STATES. THE WATER IS FROM CLOGGED DRAIN TUBES IN SUNROOF AND SOMETIMES SHRINKIAGE OF DRAIN TUBE THAT DISLODGES. VEHICLE NOW HAS A MUSTY SMELL FROM THE FREQUENT WATER IN THE VEHICLE. NOT SURE IF HIGH MOISTURE INSIDE HAS CAUSED MY CD PLAYER TO MALFUNCTION. ALSO HAVE A SHORT IN ELECTRICAL SYSTEM THAT CAUSE ME TO REPLACE 3 BATTERIES IN THE VEHICLE. ALSO THE SUNROOF MOTOR SHORTED OUT MAKING IT DIFFICULT TO REPLACE THE DRAINAGE TUBES THAT WOULD HELP CORRECT THE WATER ISSUES. HOPE SOMEONE CAN HELP.

NHTSA ID
10749784
Incident
May 22, 2005
Fuel system
Filed May 11, 2015

TL* THE CONTACT OWNS A 2003 VOLVO XC90. WHILE DRIVING AT APPROXIMATELY 55 MPH, FUEL FUMES EMITTED INTO THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT FUEL WAS ALL OVER THE EXHAUST PIPE AND THE BOTTOM OF THE FUEL TANK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP WAS CRACK AND LEAKING FUEL. THE VEHICLE WAS NOT REPAIRED. THE VIN NUMBER WAS NOT INCLUDED IN NHTSA CAMPAIGN: 09V483000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 111,000.

NHTSA ID
10715762
Incident
May 10, 2015
Mileage
111,000 mi
Fuel system
Filed Mar 17, 2015

TL* THE CONTACT OWNS A 2003 VOLVO XC90. THE CONTACT STATED THAT FUEL FUMES EMITTED IN AND AROUND THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE TECHNICIAN DIAGNOSED THAT THERE WAS A LEAK IN THE FUEL PUMP. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND CONFIRMED THAT THE VIN WAS NOT ASSOCIATED WITH NHTSA CAMPAIGN NUMBER: 09V483000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 141,000.

NHTSA ID
10694911
Incident
Mar 13, 2015
Mileage
141,000 mi
Powertrain (other)
Filed Jan 29, 2015

TRANSMISSION FAILED WITHOUT WARNING. HERE'S THE STORY, MY XC90 WAS DEALER SERVICED A WEEK AGO (PM), TOOK ON A SHORT ROAD TRIP OVER WEEKEND, FORTUNATELY MADE IT HOME BEFORE IT BROKE DOWN. WENT TO WORK UPON RETURNING FROM TRIP AND WHILE I WAS PARKING THE TRANSMISSION FAILED TO ENGAGE IN ANY GEAR. VERY UNSAFE! NO WARNING LIGHTS ILLUMINATED AND THERE WAS NO 'LIMP MODE.' THE RPMS ROSE AS IF IT WERE IN NEUTRAL. COULD HEAR A METALLIC RATTLING NOISE COMING FROM TRANSMISSION. HAD TO HAVE IT TOWED FROM WORK TO AAMCO. AAMCO STATED THE DAMAGE WAS INSIDE OF TRANSMISSION AND THEY WOULD NEED TO REMOVE AND TEAR DOWN TO SEE WHAT ISSUE IS, BUT MORE THAN LIKELY IT WAS A COMPLETE FAILURE. I JUST BOUGHT THIS CAR IN NOVEMBER AND LUCKILY BOUGHT AN AFTERMARKET WARRANTY THAT 'SHOULD' COVER EVERYTHING. ISSUE IS THE WARRANTY COMPANY WILL MORE THAN LIKELY JUST REPLACE IT WITH A USED TRANS THAT WILL FAIL IN A SHORT TIME AND I WILL HAVE TO GO THROUGH THIS AGAIN. THIS IS A MAJOR DESIGN FLAW ON THE PART OF VOLVO AND THEY SHOULD OWN UP TO IT. THE ENGINE PRODUCES TOO MUCH POWER AND THE VEHICLE IS TOO HEAVY FOR THE TRANSMISSION TO TAKE IT. THIS IS A T6 BTW, WITH THE 6 CYLINDER AND TWIN TURBO. VOLVO SHOULD HAVE A RECALL ON THIS TRANSMISSION. I HAVE SCOURED THE WEB AND SEE THIS IS AN ONGOING FREQUENT ISSUE WITH THE XC90 AND VOLVO IS LOSING WHAT WERE ONCE LOYAL CUSTOMERS. SEARCH THIS ISSUE ON THE WEB AND YOU'LL WONDER IF THERE ARE ANY XC90'S THAT DO NOT HAVE TRANSMISSION PROBLEMS. *TR

NHTSA ID
10679777
Incident
Jan 27, 2015
Mileage
92,000 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

35526.1.8

ENGINE

This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure
 Description and Service sections updated to clarify that vehicle reports are not required.

37809.1.1

This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval.
 Current items under prior approval are listed in the "Service" section

19245

This is a Technical Journal. Vehicle type and platform identification.

8501

EXTERIOR LIGHTING

This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session:
 •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V.
 •Connect to the vehicle over a wired connection using a VOE (Volvo OBD to Ethernet) adapter and perform a NEW vehicle readout.

S10303

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles.
 Volvo Car Investigations have identified that there is a pairing issue with the key fob.
 As a result, there is a possibility that the customer’s key fob is not paired to the vehicle.
 The corrective action is to download SP Software.
 S10303 affects 151 vehicles in the U.S and 5 in Canada.

S10303

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles.
 Volvo Car Investigations have identified that there is a pairing issue with the key fob.
 As a result, there is a possibility that the customer’s key fob is not paired to the vehicle.
 The corrective action is to download SP Software.
 S10303 affects 151 vehicles in the U.S and 5 in Canada.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Volvo XC90 by model year
YearComplaintsRecallsInvestigationsIssue Index
2025272058.9
2024343061.2
2023396055.7
2022294155.3
2021326167.9
2020297172.3
2019386174.0
2018473166.2
2017757171.9
20161968164.1
2015010—
2014400—
2013110034.3
2012300—
2011191045.9
2010123039.1
2009710—
2008293050.0
2007382052.2
2006533054.3
20052236454.2
20044626354.9
2003Viewing935047.0

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.