Volvo XC90: these are the most common problems

The Volvo XC90 is a luxury SUV known for its safety, Scandinavian design and spacious interior. At the same time, owners and mechanics have reported recurring problems over the years with, among other things, the transmission, electronics and air suspension. These issues can become very expensive and require targeted attention when it comes to maintenance and purchase.

Why is it important to know about these problems?

If you are considering buying a Volvo XC90 or already own one, understanding common problems helps you make well-informed decisions. You know what to look out for during a test drive, which questions to ask the seller and what maintenance costs to expect. For current owners this knowledge provides a basis for recognising early symptoms, so you can often prevent costly repairs. You can find more information about Volvo problems in our comprehensive overview of known points of attention for each model.

How reliable are the different XC90 generations?

The first-generation XC90 appeared in 2002 and was produced until 2014. These models have a mixed reputation: some owners report many years and many kilometres of trouble-free driving, while others mention regular recurring faults in the transmission and electronics. Cars built before 2008 in particular suffer from more teething troubles.

The second generation was launched in 2015 and introduced a completely new platform, modern powertrains and advanced infotainment systems. This generation scores better on average for reliability, but has its own points of attention such as software updates for the Sensus system and complex hybrid technology in the T8 version. Mild-hybrid B5 and B6 models are relatively new and so far show fewer problems. The long-term reliability is still being tested.

The five most frequently reported problems

Owners and mechanics repeatedly highlight a number of recurring complaints with the Volvo XC90:

• Jerky gear changes and delays with the automatic transmission
• Faults in the Sensus infotainment system and various electrical components
• Defects in the air suspension, especially on older models
• Increased oil consumption and problems with EGR valves on diesel engines
• Noises and wear in the four-wheel drive system and Haldex coupling

This list helps you set priorities during an inspection or when planning your own maintenance.

Transmission problems: jerks and delays

The automatic gearbox is one of the most frequently reported pain points, especially in first-generation XC90s. Owners report jerky gear changes, delayed response when pulling away and occasionally gears that refuse to engage. These complaints are more common on models with the Aisin automatic. Heavy use or little maintenance makes the problems worse.

Ageing transmission oil, wear on the clutch plates or software issues in the transmission control unit are often the underlying causes. Regular oil changes in line with the factory recommendations can prevent many problems. If complaints persist, a diagnosis by a specialist mechanic is essential. Repairs range from a software flash to a complete rebuild, with costs rising to several thousand euros.

Electronics and infotainment: faults and updates

The Sensus infotainment system (the central screen for navigation, audio and vehicle settings) in second-generation XC90s offers a wide range of functions but is also prone to software glitches. Owners report frozen touchscreens, dropping bluetooth connections and slow-responding menus. Sensors for driver-assistance systems such as blind-spot monitoring and parking assistance can also trigger error messages.

Many problems are resolved with a software update at the dealer. Keep your system up to date via over-the-air updates or regular dealer visits. Sometimes the cause is hardware-related, for example a faulty battery or poor earth connection. Check the 12V battery regularly; a weak battery causes numerous electrical problems that are often wrongly blamed on complex systems.

On the first generation, electrical faults are often traced back to corrosion in connectors or ageing control modules. These models have less advanced systems but still require attention to the basic quality of the wiring and connectors.

Air suspension: comfort versus complexity

The optional air suspension offers excellent comfort and an adjustable ride height, but it is also one of the most expensive components to repair. Older XC90s regularly suffer from leaking air springs, failing compressors and broken level sensors. Symptoms include an uneven ride height, hard jolts or a warning light on the dashboard.

Replacing an air spring costs from several hundred to well over a thousand euros per unit. A compressor is in the same price range. When buying a used XC90 with air suspension, it is worth checking the ride height on a cold start: if the car is leaning to one side or rises slowly, this already points to wear. Preventive maintenance mainly consists of avoiding heavy loads on rough roads and replacing parts in good time at the first signs of leakage.

Some owners choose, in the event of a major defect, to convert to conventional shock absorbers and springs, which can work out cheaper than repairing the air suspension system.

Engine-related points of attention for diesel, petrol and hybrid

Diesel engines in the XC90, especially the D5 versions, are known for problems with the EGR valve (a valve that recirculates exhaust gases back into the engine to reduce emissions) and the diesel particulate filter (a filter that captures soot particles from the exhaust gases). Clogged EGR valves lead to loss of power, rough idling and increased fuel consumption. Regular longer journeys at higher speeds help keep the system clean. In cases of severe contamination, cleaning or replacement is necessary, with costs ranging from several hundred to well over a thousand euros.

Petrol engines, particularly the five-cylinder T5 and T6 from the first generation, can show increased oil consumption at higher mileages. Check the oil level regularly and top up if necessary. Turbos can show wear over time; be alert for whistling noises or sudden drops in power.

The T8 plug-in hybrid (a car you can charge from the mains that can run on both electricity and petrol) combines a four-cylinder petrol engine with an electric motor and battery pack. This powertrain of engine, battery and electronics requires specialist knowledge and adapted maintenance. Owners occasionally report problems with the high-voltage battery and the inverter. Repairs are expensive and often fall outside the standard factory warranty. Make sure you have regular software updates carried out and charge the car daily to keep the battery healthy.

Four-wheel drive and differential: known weaknesses

The XC90’s four-wheel drive uses a Haldex coupling (an electronically controlled clutch that engages the rear wheels as soon as the front wheels start to slip). This coupling requires regular oil changes, something that is often overlooked. Neglecting this maintenance can lead to failed couplings, with repair costs that can run to several thousand euros.

Symptoms of problems include noises from the rear axle, vibrations or loss of traction. Some owners also report complaints about the rear differential, particularly on models with high mileage or intensive use. When buying a used XC90, it is wise to ask for the service history of the Haldex coupling and to listen for unusual noises under acceleration or when cornering during the test drive.

Chassis and suspension: wear and noises

The XC90’s chassis is designed to be robust for a large and heavy SUV, but components inevitably wear out over time. Common complaints include worn bushes in the control arms, failed wheel bearings and defective ball joints. These problems often reveal themselves through knocking or clunking noises over bumps, play in the steering or uneven tyre wear.

During an inspection, check the condition of the bushes by moving the wheels back and forth while the car is on the lift. Replace worn components in good time to prevent further damage to other parts. Costs for replacing control arm bushes or wheel bearings range from several hundred to over a thousand euros, depending on the specific part and labour time.

The anti-roll bars and their bushes also need regular attention. Defective anti-roll bar bushes cause knocking noises at low speeds over bumps. This is a relatively simple and affordable repair.

Brakes and steering: safety first

The XC90’s brakes are strong and reliable, but this heavy car does require regular maintenance. Brake discs and pads wear faster than on lighter models, especially on the T8 version due to the extra weight of the battery pack. Check the thickness of the discs and pads at least once a year and replace them in good time to prevent brake fade and longer stopping distances.

The steering system is occasionally affected by leaking power steering lines or a failed steering rack. Symptoms include heavy steering, a whine when turning or oil spots under the front of the car. Repairing the steering rack can cost from several hundred to well over a thousand euros. Check the power steering fluid level regularly and top up if necessary.

Repair costs and preventive measures

Maintenance costs for the XC90 are higher than for regular family cars. Expect to pay several hundred euros for a major service, excluding any repairs. Complex systems such as air suspension, Haldex coupling and hybrid powertrains can, if they fail, result in bills ranging from a thousand to several thousand euros.

Prevention is the best strategy:

• Follow the factory service schedule strictly, including special intervals for transmission oil and Haldex oil
• Keep software updates for infotainment and driver-assistance systems up to date
• Regularly check oil level, coolant and power steering fluid
• Have the battery tested annually, especially on models with lots of electronics
• Regularly drive longer distances to keep diesel engines and hybrid systems healthy
• Have unusual noises or warning lights investigated immediately

A reliable mechanic with Volvo experience often saves you money compared with dealer servicing, without any loss of quality.

Checklist for buying a used XC90

Thinking about buying a used Volvo XC90? Then make sure you check the following points thoroughly:

• Ask for the full service record and check whether the transmission and Haldex oil have been changed
• Test all functions of the Sensus system: navigation, bluetooth, cameras and updates
• Check whether the air suspension works correctly and whether the car is level after a cold start
• During the test drive, pay attention to jerks or delays when changing gear
• Listen for noises from the chassis, drivetrain and rear axle when cornering and accelerating
• Check the condition of the brake discs and tyres for uneven wear patterns
• For T8 models, ask about the condition of the high-voltage battery and any warranties
• Test all electrical functions: seat heating, panoramic roof, driver-assistance systems and lighting
• Check for oil leaks under the car, especially around the steering rack and engine
• If you have any doubts about the mechanical condition, have an independent inspection carried out

A thorough pre-purchase inspection prevents you from being faced with unpleasant surprises.

Is the XC90 a good choice despite these problems?

The Volvo XC90 offers a combination of safety, comfort and space that ranks highly in the luxury SUV segment. The reported problems are not unique to Volvo; many other brands with similarly complex systems have comparable points of attention. The difference lies in awareness and preventive action.

For those prepared to invest in regular maintenance and stay alert to signs of wear, the XC90 is a reliable and pleasant car. Ideally choose more recent models with a documented service history. Avoid cars with neglected maintenance or unclear provenance. With realistic expectations and careful management, the XC90 can provide many years of driving pleasure without too many worries.