One problem related to loud engine noise has 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.
A rubbing noise began in late September. I had an inspection and diagnostic at the dealership on September 23rd. They told me the front bearings and the lower engine mount pad should be replaced. The next day, while I was driving, the transmission seized. The car was towed and the dealership said they had to replace the transmission and entire coolant system. Their diagnostic specialist was unable to detect such a catastrophic failure the day before it happened. Who knows what would have happened if I was on the highway. Volvo acknowledged the problem but only paid for half of the parts and labor. I still had to come out of pocket $3000+.