Model year record

2003 Volvo XC90 recalls & problems

The 2003 Volvo XC90 has 5 safety recalls and 93 owner complaints on file with NHTSA. The most-reported problem area is power train (49 complaints).

Recalls5safety recalls

Complaints93filed by owners

Crashes · fires2 · 2reported in complaints

Injuries · deaths6 · 0reported in complaints

2003 Volvo XC90 in an NHTSA crash test — NHTSA crash test

Safety recalls

EquipmentNov 8, 2010

Electrical › Navigational system(global positioning system)

Recall 10V566000416 vehicles

Problem: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Fix: 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.

Fuel system, gasolineDec 18, 2009

Delivery › Fuel pump

Recall 09V483000158,733 vehiclesopened after NHTSA action (ODI)

Problem: 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.
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.
Fix: 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.

SteeringMay 5, 2006

Linkages › Tie rod assembly

Recall 06V155000126,743 vehicles

Problem: 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.
Risk: THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.
Fix: 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.

VisibilityApr 28, 2006

Windshield wiper/washer

Recall 06V144000122,431 vehiclesopened after NHTSA action (ODI)

Problem: ON CERTAIN VEHICLES, IF THE WIPER ARM IS ACTIVATED IN EXTREME WINTER WEATHER CONDITIONS AND WITHOUT LIFTING THE WIPER ARMS AND CLEANING THE WINDSHIELD PRIOR TO MOVING, THE WIPER ARM MIGHT SLIP ON ITS DRIVESHAFT, RESULTING IN AN INABILITY TO MOVE THE WIPERS FROM THE PARK POSITION.
Risk: INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.
Fix: DEALERS WILL REPLACE THE WIPER ARMS AND RETAINING NUTS. THE RECALL BEGAN ON SEPTEMBER 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.

Seat beltsOct 10, 2003

Rear/other

Recall 03V39100018,692 vehicles

Problem: ON CERTAIN SPORT UTILITY VEHICLES, THE SEAT BELT ATTACHMENT(S) FOR THE SECOND AND THIRD ROW SEAT(S) MAY NOT HAVE BEEN FITTED PROPERLY.
Risk: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED, INCREASING THE RISK OF INJURY.
Fix: DEALERS WILL INSPECT AND REPAIR THE SECOND AND/OR THIRD ROW SEAT BELT ATTACHMENTS. OWNER NOTIFICATION BEGAN ON DECEMBER 8, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2003 Volvo XC90 4-DR. w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2003 Volvo XC90 NHTSA side crash test — NHTSA side barrier crash test

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

XC90 FWD

18mpg combined

City / highway	16 / 22 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Automatic (S5) · Front-Wheel Drive · about $4,550/year to fuel

XC90 AWD

18mpg combined

City / highway	16 / 22 mpg
Fuel	Premium Gasoline

2.5 L · 5 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $4,550/year to fuel

XC90 AWD

16mpg combined

City / highway	14 / 19 mpg
Fuel	Premium Gasoline

2.9 L · 6 cyl · Automatic (S4) · 4-Wheel or All-Wheel Drive · about $5,150/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Power trainAutomatic transmission; Axle hubs	49	0	0	0	76,000 mi
Electrical systemIgnition; Wiring › Interior/under dash	18	0	1	1	79,000 mi
SuspensionRear; Front	10	0	0	0	55,000 mi
Engine and engine coolingEngine; Exhaust system	9	0	0	0	78,000 mi
StructureBody › Door; Frame and members	6	0	0	1	47,045 mi
Fuel system, gasolineDelivery › Fuel pump; Delivery	6	0	0	0	108,000 mi
EquipmentElectrical › Radio/tape deck/cd etc.	5	0	0	0	50,045 mi
SteeringHydraulic power assist system; Hydraulic power assist › Pump	4	1	1	1	43,813 mi
Air bags	4	1	1	1	88,150 mi
Service brakes, hydraulicFoundation components › Differential proportional valve; Foundation components › Drum	4	0	0	0	47,135 mi
Fuel/propulsion system	4	0	0	0	—
Parking brake	3	0	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Fuel/propulsion system
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.
Jun 20, 2022
Power train
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
Jan 29, 2021 · 141,000 miles
Electrical system
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…
Dec 15, 2015 · 230,000 miles
Power train
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.
Apr 10, 2014 · 114,687 miles
Structure › Body
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.
May 22, 2005
Fuel/propulsion system
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.
May 10, 2015 · 111,000 miles
Fuel/propulsion system
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.
Mar 13, 2015 · 141,000 miles
Power train
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…
Jan 27, 2015 · 92,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.