2005 Volvo XC90 Problems

What owners report

Owners of the 2005 XC90 most often write about transmission trouble — slipping, harsh shifting, warning messages and, in many cases, replacement — frequently between roughly 55,000 and 100,000 miles. A second recurring theme is the central electronic module (CEM), where water intrusion is described as causing lost wipers, lighting, gauges and accessories; fuel odor and pump problems, balance shaft bearing noise in V8 models, and cooling-system leaks round out the picture. Many complaints come from later owners at higher mileage.

1. 1
   Transmission and drivetrain

   Transmission slipping, hard shifting and failure

   • 62 complaints (28%)
   • median 72,350 mi at 5.5 yrs old (59 state mileage)
   • owner-quoted repair $5,200 (median of 15 quotes)
   • filed 2007–2019

   Complaints describe the transmission slipping out of gear, revving without acceleration, shifting harshly or banging between gears, sometimes accompanied by a transmission service urgent message. Several owners say the vehicle lost power or slowed unexpectedly while driving, and that dealers first tried fluid changes or software updates before concluding the unit needed rebuilding or replacement. A number of reports involve the T6 version, and some owners describe a replacement unit failing again later. Mostly reported between about 55,000 and 100,000 miles, with a few at higher mileage; several owners mention symptoms appearing on inclines or during acceleration into traffic.

   What to check: Test drive from cold through several up- and downshifts and at highway speed, watching for flare, harsh engagement or warning messages. Ask for transmission service records and whether fluid or software work has already been done.

   2 excerpts from owner complaints in NHTSA records

   “My car is a 2005, transmission never had a indicator light showing it needed service, now my transmission needs replacing at 131,000 miles. I know of several others with the same situation. Volvo claims they are the only ones that can service the transmission. I don't trust them and now it's being served at aamco.”

   NHTSA complaint #11012322, filed 2017-08, 131,000 miles

   “My car was at traffic light, on green light, I tried to accelerate , I heard a big noise from somewhere in engine area. After that noise, a light come on with a message transmission service urgent . The car has real hard time to accelerate. Even at 4000 RPM, it did not accelerate. Browse on internet for 3 hours and finally come to know that this particular model has transmission problem.”

   NHTSA complaint #10476961, filed 2012-09, 96,005 miles
2. 2
   Electrical system

   Water in the central electronic module (CEM)

   • 38 complaints (17%)
   • median 104,000 mi at 7.3 yrs old (34 state mileage)
   • 1 mention a crash, fire or injury
   • owner-quoted repair $4,400 (median of 6 quotes)
   • filed 2009–2025

   Owners describe intermittent electrical failures that often follow rain or a car wash: windshield wipers stopping or running continuously, headlights or turn signals failing, dashboard gauges and warning lights going blank, and audio or climate controls behaving erratically. In several complaints a mechanic or dealer traced the problem to the central electronic module and water reaching its connectors, and the fix was module replacement, sometimes with wiring harness work. Some owners report the same faults returning after an earlier module replacement. Scattered from roughly 50,000 to 130,000 miles; several owners link the onset to wet weather, rainstorms or washing the vehicle.

   Recall 07V221000Recall 06V1440002 related service bulletins

   What to check: Check that wipers, all exterior lights, turn signals, gauges and the radio work, ideally after the car has been driven in rain or washed. Ask whether the CEM has ever been replaced and whether the cowl drains and seals have been inspected.

   2 excerpts from owner complaints in NHTSA records

   “My Volvo XC90 also has been diagnosed with cem problems after various symptoms began to arise. After going through a car wash, the display began showing various messages. The biggest problem is the the windshield wipers stopped working. I have ordered a new cem and intend to replace it . I am an attorney. If this vehicle continues to fail after the cem is replaced, I intend to take further legal action, especially in light of the reports and complaints I have read on this website. …”

   NHTSA complaint #10788492, filed 2015-11, 210,000 miles

   “I'd like to add my complaint to the list of those already reporting the abrupt loss of all electronics, including windshield wipers and all dashboard gauges, during a rainstorm. My issue was also identified as a prematurely corroded central electronic module (cem) caused by a design flaw allowing water to access the cem connector. I'm shocked to find out Volvo knew about this in 2005, well within the warranty period for most of these affected vehicles, and did nothing to correct or even alert their owners. …”

   NHTSA complaint #10418848, filed 2011-08, 93,834 miles
3. 3
   Engine

   Engine noise or failure from balance shaft bearing (V8)

   • 36 complaints (16%)
   • median 85,000 mi at 6.8 yrs old (35 state mileage)
   • owner-quoted repair $4,100 (median of 18 quotes)
   • filed 2010–2019

   Owners of V8 cars describe a grinding, rattling or knocking noise from the engine that worsens over a short period, sometimes without any warning light. According to the complaints, mechanics identified the balance shaft bearing as the source, with water intrusion into the bearing cited as the reason it deteriorates, and repairs ranged from replacing the shaft with the cylinder head removed to full engine replacement. Several owners say an independent shop sent them to a dealer because only the dealer was authorized for the work. Generally reported between about 50,000 and 120,000 miles, with a few earlier; all reports involve the V8 engine.

   1 related service bulletin

   What to check: On a V8 car, listen for grinding or rattling at idle and at steady highway speed, and ask for service records showing whether the balance shaft has been inspected or replaced.

   2 excerpts from owner complaints in NHTSA records

   “At 111,000 thousand miles the counter balance shaft bearing went inside the motor. I did a little research on line and found out that it is a design problem, that Volvo knows about. It could cost any where from $5000.00 to $15000.00. I believe that they should be forced to do a recall for this known problem, and help there customers with the repairs. Thank you for your help in this matter.”

   NHTSA complaint #10498317, filed 2013-02, 111,000 miles

   “I noticed a grinding noise while driving at normal highway speed as it got worse over the next day or so I brought it to my local Volvo specialist. After some research I was told that the problem was with the balance shaft and was specific to the 2005 XC90 v8. I contacted Volvo north america and received no compensation or even satisfactory customer service. My local Volvo tech recommended I bring the car to the Volvo dealer, who were the only one's authorized to do the repair. …”

   NHTSA complaint #10466349, filed 2012-07, 64,983 miles
4. 4
   Fuel system

   Fuel odor, leaks and fuel pump problems

   • 29 complaints (13%)
   • median 104,000 mi at 10.1 yrs old (26 state mileage)
   • filed 2006–2023

   Complaints describe a strong fuel smell inside or around the vehicle, especially after filling up, and in some cases visible fuel leakage. Owners also report stalling, hard starting, check-engine lights and, after diagnosis, a fuel pump, fuel pump controller or fuel line needing replacement. A few note that their vehicle was not covered by the fuel pump campaign that applied to other cars of this era, and one owner mentions a controller mounted near the rear wheel well that corroded from road salt and moisture. Mostly reported between about 70,000 and 140,000 miles, often noticed after refueling or while driving at ordinary speeds.

   Recall 09V483000

   What to check: Smell for fuel around the filler neck and under the rear of the car after a fill-up, and ask whether the fuel pump or controller has been replaced. Check whether the car is covered by or has had the fuel pump campaign performed.

   2 excerpts from owner complaints in NHTSA records

   “Strong fuel odor within cabin after fuel fillup, there is a recall on fuel pumps due to fire risk on this exact model, just not on my vehicle. Should I wait for a fire before a recall is issued?”

   NHTSA complaint #10443420, filed 2012-01, 71,000 miles

   “2005 XC90 v8 stalled in traffic. Would not restart, but starter would crank. Fuel pump controller was found to be internally corroded and filled with dried salt. This controller is mounted forward of the right rear wheel well. Many instances of this controller failing due to salt / moisture ingress have been reported by other owners. The controller was relocated to the inside of the vehicle some model years later.”

   NHTSA complaint #10668406, filed 2014-12, 90,000 miles
5. 5
   Engine cooling

   Coolant leaks from heater pipes and cooling system

   Mentioned in 4 of 60 sampled complaints

   Complaints describe coolant loss and leaks traced to the heater pipes that pass through the firewall, with one owner noting corrosion on a relatively young vehicle and dealer quotes that were largely labor for removing the dashboard. Other reports include coolant and overheating concerns, and Volvo service information includes a procedure for cleaning the cooling system when oil is found in it. Reported from about 50,000 miles upward, with several owners noting coolant smell or low coolant level between services.

   3 related service bulletins

   What to check: Check the coolant level and look for crusty residue or a sweet smell near the firewall and under the car, and ask whether the heater pipes or cooling system have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “The vehicle was bought back in 10/31/04. Within weeks of having the vehicle, we noticed lost of power and performances if the vehicle. We called the dealer about it and said that it might just be due to the gas cap. As it turned out they had to replace a solenoid which part of the starter or some type of firing mechanism for the engine. After that problem was fixed, we had to continually bring the vehicle back to the dealer for the check engine constantly coming on. This went on for numerous times until they found a relay problem. …”

   NHTSA complaint #10171029, filed 2006-10, 37,300 miles

   “We own a 2005 Volvo XC90 and it has 54k miles on it. We heard a whining sound from the rear and took it to the dealer and they said the rear hub bearings need to be changed. We were not convinced and took it to our auto mechanic who works on our avalon, he looked at it and after spending 5hrs on it came to the conclusion that it was the rear differential. We went back to the Volvo dealer and asked him to check again and said it may be the transmission. They came back and said yes it is the rear differential and it needs to be replaced. …”

   NHTSA complaint #10297370, filed 2009-12, 54,000 miles

Buying note. A 2005 XC90 can still be a usable vehicle, but the transmission and CEM faults are the expensive ones, so a pre-purchase inspection that covers both, plus a cold test drive and a check for fuel and coolant smells, is worth the cost. Service records showing transmission and electrical work are more telling than mileage alone.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.