VehicleVerdict

2004 Volvo XC90 electrical system problems

The 2004 Volvo XC90 has 172 electrical system complaints filed with NHTSA — 26% of the year's total, and up sharply from the prior model year.

172

Electrical System complaints

26%

Share of year

3

Crash-involved

1

Related recalls

Electrical System complaints by year

XC90 electrical system complaints by model year172 complaints2003: 23 complaints2004: 172 complaints2005: 56 complaints2006: 19 complaints2007: 16 complaints2008: 11 complaints2009: 3 complaints2011: 5 complaints2012: 2 complaints2013: 3 complaints2016: 63 complaints2017: 16 complaints2018: 12 complaints2019: 11 complaints2020: 7 complaints2021: 8 complaints2022: 13 complaints2023: 9 complaints2024: 15 complaints2025: 5 complaints
XC90 electrical system complaints by model year. Red bars are years to avoid.

Related recalls

10V566000Electrical SystemNovember 8, 2010 · 416 units

Defect

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

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.

What owners report

“ENGINE PASSENGER SIDE CAUGHT FIRE IN THE AN ELECTRICAL COMPONENT, FLAMES SHOOTING OUT THE WHEEL WELL. OTHER DRIVERS FLAGGED TO PULL OVER, TURNED OFF IGNITION KEY AND REMOVED TO GET OUT OF VEHICLE. ENGINE WOULD NOT TURN OFF, CALLED THE FIRE DEPARTMENT TO EXTINGUISH THE FIRE FOR FEAR OF EXPLOSION.…”

Complaint filed with NHTSA · Electrical System · July 4, 2013 · fire

Common questions

How many electrical system complaints does the 2004 Volvo XC90 have?

NHTSA has 172 complaints about the 2004 Volvo XC90 electrical system — 26% of all complaints filed for that model year.

Are there recalls for the 2004 Volvo XC90 electrical system?

Yes — 1 NHTSA recall campaign for this model year is tied to the electrical system: 10V566000.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.