2004 Volvo XC90 — MOT failures & pass rate
17,770 MOT tests on the 2004 Volvo XC90 are in this dataset, and 70.7% of them passed. Against large SUVs of a similar age (25.3% fail rate), the 2004 XC90 comes out 4.1pp worse. Failures cluster in lighting & signalling, brakes and suspension.
What the MOT record shows
One area stands out: lighting & signalling, recorded in 20.9% of tests against 17.7% for the next-worst category.
At component level the recurring items are position lamp, headlamp aim and pins and bushes — position lamp alone was recorded 1,908 times.
Mileage is the strongest signal on the record: 23.4% of 0-30k cars fail, rising to 30.0% once past 150k.
The petrol cars hold up better: 27.6% fail against 29.6% for diesel, a 1.9-point gap across 17,752 tests.
Suspension is the most common advisory, noted on 46.7% of tests — work that passed today but is likely due soon.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 20.9% | 3,709 |
| 2 | Brakes | 17.7% | 3,148 |
| 3 | Suspension | 13.5% | 2,402 |
| 4 | Steering | 5.0% | 879 |
| 5 | Tyres | 5.0% | 879 |
| 6 | Visibility | 4.3% | 757 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Position lamp | 1,908 |
| 2 | Headlamp aim | 1,884 |
| 3 | Pins and bushes | 1,400 |
| 4 | Headlamp | 1,363 |
| 5 | Rbt (sp) | 1,360 |
| 6 | Ball joint | 1,020 |
Top advisory categories
Advisories aren't failures, but they flag work likely needed soon — useful when budgeting.
| # | Category | % of tests with advisory | Tests |
|---|---|---|---|
| 1 | Suspension | 46.7% | 8,291 |
| 2 | Brakes | 28.6% | 5,082 |
| 3 | Tyres | 27.8% | 4,946 |
| 4 | Lighting & signalling | 26.0% | 4,627 |
| 5 | Other defects | 24.0% | 4,263 |
| 6 | Emissions & environmental | 14.6% | 2,597 |
Failure rate by mileage
Higher-mileage cars tend to fail more — often the most useful guide to real condition.
| Mileage band | Tests | Fail rate |
|---|---|---|
| 0-30k | 64 | 23.4% |
| 30-60k | 153 | 25.5% |
| 60-90k | 758 | 27.3% |
| 90-120k | 2,302 | 27.6% |
| 120-150k | 4,468 | 29.0% |
| 150k+ | 9,963 | 30.0% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Diesel | 15,655 | 29.6% |
| Petrol | 2,097 | 27.6% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 5,181 | 29.8% |
| 2022 | 4,410 | 29.3% |
| 2023 | 3,545 | 29.0% |
| 2024 | 2,678 | 29.3% |
| 2025 | 1,956 | 28.7% |
What to check before buying a 2004 XC90
The failure pattern for this year is specific enough to inspect against: lighting & signalling accounted for 20.9% of tests. Start there.
- Lighting & signalling (20.9% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Brakes (17.7% of tests): Pads/discs are routine wear; binding, imbalance or corroded pipes are more serious — test for pulling under braking. Typical repair: £100–£350 per axle.
- Suspension (13.5% of tests): Worn drop links, bushes, springs or shocks — listen for knocks over bumps and check for uneven tyre wear. Typical repair: £150–£450 per corner.
Repair costs are rough UK ballpark ranges to set expectations, not quotes — actual prices vary widely by car, parts and garage.
Frequently asked questions
How many 2004 Volvo XC90s pass their MOT?
70.7% of the 17,770 2004 Volvo XC90 MOT tests in this dataset passed — a 29.3% fail rate.
What is the most common MOT failure on a 2004 Volvo XC90?
Lighting & signalling, recorded in 20.9% of tests, followed by brakes (17.7%).
Does the 2004 XC90 get worse with mileage?
Its MOT fail rate rises from 23.4% in the 0-30k band to 30.0% in the 150k+ band.
Methodology & source. Based on 17,770 MOT tests. Dataset: DVSA MOT testing data (2021,2022,2023,2024,2025). Data last updated 2026-07-27. Figures reflect MOT-testable defects only — read the methodology for how these are calculated and what they don't measure.