Skip to content
Body and structurePart report

2004 Volvo XC90 Body and structure Problems

Complaints
14about this part
Share
3%of 462 total for the year
Median mileage
99,608miles
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.

NHTSA recorded 14 complaints about the body and structure of the 2004 Volvo XC90, 3% of the 462 complaints for this model year. Where a mileage was given, the median is 99,608 miles.

Fewer than 15 complaints name this part, so treat the figures as a rough indication only.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“On june 2013, my interior door handles both front and back all began to break. All interior door handles both front and back began to brake around a 2 1/2 month period, at different times while I was exiting my car. This is ridiculous. All handles breaking around the same time. I have to now lower my window and reach threw the outside to open the door. This problem needs to be addressed and recalled. What I have read online, I am not the only one with this problem. There are a numerous amount of vehicles with the same issue. This can be a huge safety issue. …”

NHTSA complaint #10551687, filed 2013-11, 110,255 miles

“The sunroof drain has a design flaw that can cause water to enter the passenger compartment and/or electrical systems. This can present simply as water on the floor boards. But it can also present in more subtle ways with water coming in contact with electrical systems and being drawn throughout the car through copper wires acting as conduit (this effects speaker quality, radio function, cruise control function etc). Most importantly, water can accumulate in the compartment under the front passenger seat that houses the dynamic stability traction control system putting safety at risk. …”

NHTSA complaint #10476587, filed 2012-09, 90,000 miles

“Upon closing the hatchback it came down with such force that it struck the consumer on the head. Consumer sustained a hair line neck fracture which was diagnosed by a doctor.”

NHTSA complaint #10063473, filed 2004-05, 9,000 miles

“A rain storm caused flooding into my 2004 Volvo XC90 destroying the interior. The water damage came into the car from the sun roof I was told by a Volvo service advisor that the drain in the sun roof was clogged which caused the interior flood. The problem is that during routine Volvo maintenance this so called drained was not cleaned. I was never told that there was a drain in the sun roof . This problem cost $1900.00 and lost of my car for four days . …”

NHTSA complaint #10244692, filed 2008-10

“Last year(2013) I noticed when it rain, my driver side floor will be occasionally damped. It was random and didn't happen everytime it rained, so I blew it off. As spring of 2014 approaches & the rain becomes more frequent in illinois, my driver floor becomes more & more wet, not damped but soaking wet. Puddle of water that is. Im not sure what it is, but as I research the problem I find several complaints of the issue being a sunroof drain issue. My issue is increasing & if someone can provide more information on this it would be greatly appreciated, because my carpet is ruined & smelly.”

NHTSA complaint #10597755, filed 2014-06

Related service bulletins

Body and structure: other model years

YearComplaintsShare of year
202413%
202325%
202113%
202039%
2019410%
201848%
201779%
20162312%
2013218%
201115%
2010217%
2009114%
200813%
200713%
200636%
200542%
2004143%
200366%

Other parts of the 2004 Volvo XC90

Electrical system
158 complaints
Transmission and drivetrain
145 complaints
Fuel system
77 complaints
Exterior lighting
32 complaints
Air bags
31 complaints
Engine
28 complaints
Engine cooling
24 complaints
Suspension
23 complaints
Steering
20 complaints
Brakes
19 complaints
Other or unknown
17 complaints
Vehicle speed control
17 complaints

← All problems reported for the 2004 Volvo XC90

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology