Used car guide

2004 Volvo XC90: common problems and what to check

What gets flagged at MOT on 2004 Volvo XC90s, from 1,561 tests in 2025, plus known faults and what to look at before you buy one.

1,561MOT tests in 2025
56%pass first time (all 2004 cars: 58%)
7,800typical miles a year
2.6×the usual rate for suspension arm bushes and joints

What stands out

Parts flagged at MOT more often on 2004 Volvo XC90s than on all cars registered in 2004.

  • Suspension arm bushes and joints2.6× usual
    Volvo XC90
    24.8% All 2004 cars
    9.5%

    Failed outright at MOT: 5.4%, against 2% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £120–£180 (one arm) ClickMechanic

    At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

  • Steering rack inner joints4.8× usual
    Volvo XC90
    18.4% All 2004 cars
    3.8%

    Failed outright at MOT: 0%, against 0% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £100–£450 our estimate

    At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

  • Sub-frame2.7× usual
    Volvo XC90
    16.7% All 2004 cars
    6.2%

    Failed outright at MOT: 1%, against 0.3% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £300–£1,000 our estimate

    At the viewing: Look underneath at the frame the suspension bolts to. Flaky rust or holes are expensive to fix.

  • Number plate lights1.8× usual
    Volvo XC90
    14.3% All 2004 cars
    8%

    Failed outright at MOT: 3.7%, against 2.2% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £5–£40 our estimate

    At the viewing: Check the number plate lights work and the plates are clean and legal.

Better than most

Rigid brake pipes: 2.8% here, against 17.1% of all 2004 cars. Rust around suspension or steering mountings: 1.5% here, against 6.6% of all 2004 cars.

By area

The share of 2004 Volvo XC90 MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

  • Suspension
    60% of testsRough price £120–£400

    At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

  • Lights and electrics
    49% of testsRough price £10–£80

    At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

  • Brakes
    42% of testsRough price £150–£350

    At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

  • Tyres
    32% of testsRough price £70–£150

    At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

  • Steering
    22% of testsRough price £100–£450

    At the viewing: On a straight road the steering wheel should sit straight. Feel for play or knocking when turning.

  • Oil and fluid leaks
    20% of testsRough price £80–£600

    At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

Looking at a Volvo XC90?

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Other years

YearMOT testsMost flagged
20226,274Tyres 29%
20216,786Tyres 28%
20204,839Tyres 30%
20197,095Tyres 29%
20186,228Tyres 27%
20175,495Tyres 28%
20165,220Suspension 31%
20152,714Tyres 28%
20142,268Tyres 30%
20132,396Brakes 30%
20122,859Brakes 33%
20114,096Lights and electrics 34%
20105,552Suspension 38%
20093,021Suspension 46%
20081,392Suspension 52%
20072,096Suspension 54%
20061,947Suspension 56%
20052,374Suspension 59%
2003500Suspension 63%

Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2004 Volvo XC90s registered in 2004. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score