Three problems related to body have been reported for the 2004 Volvo XC90. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Volvo XC90 based on all problems reported for the 2004 XC90.
The rear right door cannot be open from inside the car. It opens fine from outside. I am aware there is a child safety lock, but in this case the problem is somewhere else. Regardless of the child safety lock position, the door cannot be open. This is a hazard, because in case oof an accident the passenger will e trapped inside the car.
Sunroof "exploded" while driving on the highway. Nothing hit it.
Our 2004 Volvo xc-90 developed a warning light that the stability control was inactive. In addition, we experienced a "sloshing" sound in the passenger compartment akin to a bottle of water rolling around the back. Upon inspection it was determined that the yaw sensor was damaged due to corrosion from defective sun-roof drains which allowed water intrusion into the vehicle body. No external leaks or issues were evident and the issue was well described upon an internet search.