Three problems related to transfer case have been reported for the 2003 Volvo XC90. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Volvo XC90 based on all problems reported for the 2003 XC90.
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.
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.
I have had this vehicle from 64,000 miles to 75,000 miles and have replaced the following - rear wheel bearings, low beam headlights 4 times, and now the angle gear has gone at 75,000 miles - not a very reliable used car.