Three problems related to power train driveline 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.
Vehicle has already had the transmission replaced at least once by previous owner. It went out again on us at about 70,000 miles. Had transmission replaced with "new high class Volvo parts" transmission. Now the engine is 3 times louder than before and we're in some serious money for our car. We're very disappointed.
Transmission replaced two times, at approx. 38,000 and at about 48,000 miles. Units start slipping when shifting to second gear and leave you right where you are until they decide to rengage. Ball joints and all four hubs replaced by 50,000 miles. Axles (front) need replacing now at 70,000 miles. Sway bar ends replaced at 55,000 miles. This is the neediest vehicle I have ever owned. Front bearings on drive shaft replaced last month, worn since abut fifteen thousand miles, finally got so loud that we could shake the drive shaft and get a quarter of play at the bearing set.
I have my 2004 Xc90 t6. At about 34k miles a noticeable 'thrum' began somewhere in the drivetrain. Original diagnosis was worn tires. After replacing tires, the noise has become worse. Now at 35k miles is very loud. New diagnosis is failing wheel bearing. A bit of research indicates I am not the only Xc90 owner with a wheel bearing failure. Wheel bearing failures at 35k miles this should be declares a defect and recalled. Please research this problem.