2004 Volvo XC90 2.4L Diesel · KA04 DCA

The vehicle remains roadworthy but the maintenance history reveals a worsening trend in suspension wear and persistent structural corrosion. While the most recent test in October 2025 at 172,794 miles passed, the tester identified a new issue regarding play in the steering rack inner joints. This follows recurring failures of front anti-roll bar linkage ball joints, which were flagged in both 2024 and 2025, indicating that while some components were replaced, the overall front suspension continues to degrade or requires attention beyond the steering assembly. At 172,794 miles over 22 years, the XC90 averages approximately 7,854 miles per year, which is consistent with typical light use for a large SUV. The data shows steady usage patterns, with roughly 2,600 miles covered between the 2024 and 2025 tests. However, the low annual mileage has not prevented the vehicle from age-related degradation, as evidenced by the consistent presence of perished rubber bushes and corroded components despite the relatively low total distance driven. A buyer must prioritize a thorough inspection of the structural integrity of the rear sub-frame and integral body structure. These areas have been flagged for corrosion since 2022, and although the 2025 report noted the rigidity is not yet significantly reduced, the persistent nature of this advisory suggests an ongoing process of oxidation. The front suspension also requires close scrutiny; the transition from perished ball joint dust covers and worn bushes to play in steering rack inner joints suggests that the front-end components are nearing the end of their service life.