RecallRepo

2005 Volvo XC90 Recalls

Recalls on record Updated July 2026

The 2005 Volvo XC90 has 6 NHTSA recall campaigns affecting an estimated 460,793 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 304 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.

Recall campaigns

EQUIPMENT 10V566000 2010-11-08 416 affected
Defect

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence

AN OVERHEATED BATTERY COULD LEAD TO A FIRE.

Remedy

VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE…

FUEL SYSTEM, GASOLINE 09V483000 2009-12-18 158,733 affected
Defect

VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH…

Consequence

IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy

DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

ELECTRICAL SYSTEM 07V221000 2007-05-25 42,211 affected
Defect

ON CERTAIN PASSENGER VEHICLES, IT HAS BEEN DETERMINED THAT WHILE DOING BATTERY MAINTENANCE THE JACK'S CRANK HANDLE CAN BE MISPLACED UNDER A BRACKET WHICH RETAINS THE BATTERY.

Consequence

MISPLACEMENT OF THE JACK'S CRANK HANDLE CAN POSE A SAFETY RISK AS IT CAN RESULT IN A SHORT CIRCUIT OF THE BATTERY WHICH COULD THEN LEAD TO A FIRE.

Remedy

DEALERS WILL INSPECT AND ENSURE PROPER PLACEMENT OF THE JACK CRANK HANDLE AND A WARNING LABEL WITH APPROVED TEXT WILL BE AFFIXED TO THE BRACKET WHICH RETAINS THE BATTERY. THIS WARNING LABEL WILL INFORM AN OPERATOR NOT TO PLACE THE JACK CRANK HANDLE BETWEEN THE BRACKET AND THE BATTERY FREE OF CHARGE. THE RECALL…

STEERING 06V155000 2006-05-05 126,743 affected
Defect

ON CERTAIN PASSENGER VEHICLES,THE OUTER TIE ROD BALL JOINT CAN DEFORM AT HIGH LOADS CAUSING A LOSS OF THE CLAMPING FORCE AND THE NUT MAY LOOSEN, WHICH MAY EVENTUALLY LEAD TO A FATIGUE FRACTURE OF THE OUTER TIE ROD BALL JOINT.

Consequence

THE DRIVER MAY NOTICE THAT THE VEHICLE IS DIFFICULT TO MANEUVER INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE THE OUTER BALL JOINT TIE RODS WITH IMPROVED OUTER BALL JOINT TIE RODS FREE OF CHARGE. THE RECALL BEGAN ON JUNE 23, 2006. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

VISIBILITY 06V144000 2006-04-28 122,431 affected
Defect

ON CERTAIN VEHICLES, IF THE WIPER ARM IS ACTIVATED IN EXTREME WINTER WEATHER CONDITIONS AND WITHOUT LIFTING THE WIPER ARMS AND CLEANING THE WINDSHIELD PRIOR TO MOVING, THE WIPER ARM MIGHT SLIP ON ITS DRIVESHAFT, RESULTING IN AN INABILITY TO MOVE THE WIPERS FROM THE PARK POSITION.

Consequence

INOPERATIVE WIPERS UNDER INCLEMENT WEATHER CONDITIONS COULD CAUSE A CRASH DUE TO IMPAIRED VISIBILITY.

Remedy

DEALERS WILL REPLACE THE WIPER ARMS AND RETAINING NUTS. THE RECALL BEGAN ON SEPTEMBER 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.

ELECTRICAL SYSTEM 05V529000 2005-11-17 10,259 affected
Defect

ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, DUE TO AN ERROR IN THE FACTORY ASSEMBLY INSTRUCTION, THE B+TERMINAL MAY BE IN CONFLICT WITH THE STARTER MOTOR SOLENOID. IF THIS OCCURS, THE CONFLICT BETWEEN THE B+TERMINAL AND THE STARTER MOTOR SOLENOID MAY DEVELOP INTO A SHORT CIRCUIT OF THE BATTERY CABLE TO GROUND.

Consequence

SMOKE MAY APPEAR FROM UNDER THE HOOD AND IT MAY BE IMPOSSIBLE TO START THE CAR. IF THE SHORT CIRCUIT HAPPENS DURING DRIVING, ELECTRICAL POWER COULD BE LOST RESULTING IN THE WARNING LAMPS BEING DEACTIVATED. AN ELECTRICAL SHORT COULD RESULT IN A FIRE.

Remedy

DEALERS WILL INSPECT AND INCREASE DISTANCE BETWEEN THE B+TERMINAL AND THE STARTER MOTOR SOLENOID BY ADJUSTING THE TERMINAL. THE RECALL BEGAN ON JANUARY 31, 2006. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

Complaints by component

ELECTRICAL SYSTEM
50
1crashes2fires
POWER TRAIN:AUTOMATIC TRANSMISSION
38
ENGINE
29
1fires
EXTERIOR LIGHTING
24
1crashes
ENGINE AND ENGINE COOLING
23
FUEL/PROPULSION SYSTEM
22
1fires
POWER TRAIN
21
ENGINE AND ENGINE COOLING:ENGINE
12
UNKNOWN OR OTHER
9
FUEL SYSTEM, GASOLINE
8
Total complaints304

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“I was getting off the highway and made a left turn. As I was accelerating the motor gentle cut off.. (you wouldnt even notice if you wasnt driving) full traffic was behind me, so luckily I was able to get out of the way and pull to shoulder. It was the day before christmas and car hasn't ran…”

ELECTRICAL SYSTEM · reported 2024-12-24

“I was getting off the highway and made a left turn. As I was accelerating the motor gentle cut off.. (you wouldnt even notice if you wasnt driving) full traffic was behind me, so luckily I was able to get out of the way and pull to shoulder. It was the day before christmas and car hasn't ran…”

AIR BAGS · reported 2024-12-24

“I was getting off the highway and made a left turn. As I was accelerating the motor gentle cut off.. (you wouldnt even notice if you wasnt driving) full traffic was behind me, so luckily I was able to get out of the way and pull to shoulder. It was the day before christmas and car hasn't ran…”

EXTERIOR LIGHTING · reported 2024-12-24

“I’ve had to change my fuel injection pump and catalytic convert twice on one year.”

FUEL/PROPULSION SYSTEM · reported 2023-07-15

“I’ve had to change my fuel injection pump and catalytic convert twice on one year.”

ENGINE · reported 2023-07-15

“I’ve had to change my fuel injection pump and catalytic convert twice on one year.”

UNKNOWN OR OTHER · reported 2023-07-15

“Adas, air bar warning lights/urgent and high gas fumes coming out from the rear seats when fully filled gas. We had called [REDACTED] and guided us to plug in our vin [xxx] on www.volvocars.com and nothing showed as far as recall and told us that these recalls expired and our 2005 volvo are not…”

FUEL/PROPULSION SYSTEM · reported 2023-05-29

“Water is leaking from the windshield into the driver and passenger side inside on the window obstructing my view while driving. Cannot drive the vehicle while it’s raining. Serious safety problem! Please recall and fix all volvos with this problem.”

VISIBILITY/WIPER · reported 2023-01-05

Defect investigations

Investigation EA06006 Opened 2006-03-21 · closed 2007-06-14

VOLVO XC90 BATTERY CABLE FAILURES

DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY…

Investigation EA06006 Opened 2006-03-21 · closed 2007-06-14

VOLVO XC90 BATTERY CABLE FAILURES

DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY…

Investigation EA06006 Opened 2006-03-21 · closed 2007-06-14

VOLVO XC90 BATTERY CABLE FAILURES

DURING PE05-057 AND EA06-006 ODI IDENTIFIED TWO CONDITIONS INVOLVING THE POSITIVE BATTERY CABLE IN MODEL YEAR (MY) 2005 VOLVO XC90 SPORT UTILITY VEHICLES THAT COULD RESULT IN A VEHICLE FIRE:(1) POSITIVE BATTERY CABLE GROUNDING TO THE STARTER SOLENOID HOUSING; AND (2) MISPLACED JACK CRANK HANDLES UNDER THE BATTERY…

Investigation PE05057 Opened 2005-11-02 · closed 2006-03-23

VOLVO XC90 BATTERY CABLE FAILURES

THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE…

Investigation PE05057 Opened 2005-11-02 · closed 2006-03-23

VOLVO XC90 BATTERY CABLE FAILURES

THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE…

Investigation PE05057 Opened 2005-11-02 · closed 2006-03-23

VOLVO XC90 BATTERY CABLE FAILURES

THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE…

Investigation PE05057 Opened 2005-11-02 · closed 2006-03-23

VOLVO XC90 BATTERY CABLE FAILURES

THE OFFICE OF DEFECT INVESTIGATIONS OPENED A PRELIMINARY EVALUATION, PE05-057 BASED ON EARLY WARNING DATA SUBMITTED TO ODI BY VOLVO. THE DATA CONTAINED FIELD REPORTS OF THERMAL FAILURES OF THE POSITIVE BATTERY CABLE. ON NOVEMBER 17, 2005, VOLVO NOTIFIED ODI THAT IT HAD IDENTIFIED A SAFETY DEFECT IN THE POSITIVE…

Investigation PE05064 Opened 2005-12-02 · closed 2006-05-10

WINDSHIELD WIPER ARM PERFORMANCE

THE MANUFACTURER NOTIFIED NHTSA BY LETTER DATED APRIL 21, 2006, THAT A SAFETY RECALL HAS BEEN INITIATED FOR CORRECTION OF THIS PROBLEM ON CERTAIN MODEL YEAR 2003 - 2006 VOLVO XC90 VEHICLES. THE RECALL AFFECTS APPROXIMATELY 122,400 SUBJECT VEHICLES PRODUCED BETWEEN AUGUST 2002 AND OCTOBER 2005.NHTSA HAS ASSIGNED NO.…

Investigation PE10025 Opened 2010-07-20 · closed 2010-11-22

Central Electronic Module Failure

Volvo acknowledged a problem affecting some subject vehicles involving water seepage into the plenum box area in the engine compartment.When this occurs water may enter into the interior / passenger compartment and track along the wiring harness for the Central Electronic Module (CEM), the device that controls many…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2005 Volvo XC90 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.