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2004 Volvo S60

Owner reports · Recalls · Investigations

More warning signs than most S60 years

Owner complaints for the 2004 Volvo S60 are substantially higher than the model-year median of 20.5.

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When problems were reported

Mileage at the reported incident

173 reports with mileage · 25 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine And Engine Cooling. Review the 63 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 30 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 22 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

12 crash reports12 fire reports8 injury reports

Engine And Engine Cooling complaints

63 reports
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60,000 miles · Sep 2, 2007
Engine And Engine Cooling

I HAVE A 2004 VOLVO S60. IN THE PAST ONE YEAR IT KEEPS STALLING BOTH IN MOTION AND WHEN GOING INTO DRIVE FROM PARK. THIS CREATES A DANGEROUS SITUATION WHILE OPERATING THE VEHICLE, ESPECIALLY WHEN IN MOTION AT HIGHWAY SPEEDS. I HAVE TAKEN THE VEHICLE TO VOLVO AUTHORIZED SERVICE TWICE WITH NO RESOLUTION. THE LAST STALL WAS ON AUGU…

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I HAVE A 2004 VOLVO S60. IN THE PAST ONE YEAR IT KEEPS STALLING BOTH IN MOTION AND WHEN GOING INTO DRIVE FROM PARK. THIS CREATES A DANGEROUS SITUATION WHILE OPERATING THE VEHICLE, ESPECIALLY WHEN IN MOTION AT HIGHWAY SPEEDS. I HAVE TAKEN THE VEHICLE TO VOLVO AUTHORIZED SERVICE TWICE WITH NO RESOLUTION. THE LAST STALL WAS ON AUGUST 30, 2007 RESULTING IN THE CAR BEING TOWED TO VOLVO SERVICE. A RECALL WAS ISSUED ON 2004 S40 DUE TO A SIMILAR COMPLAINT, BUT I WAS TOLD THAT THE RECALL DID NOT APPLY SINCE THE VEHICLE WAS AN ALL WHEEL DRIVE. *TR

NHTSA ODI #10201715

7,800 miles · Jul 20, 2007
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 60 MPH, THE VEHICLE LOST POWER STEERING AND THE BRAKES FAILED. THE CONTACT SHIFTED INTO NEUTRAL AND THEN TURNED OFF AND RESTARTED THE VEHICLE. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE CURRENT MILEAGE IS 32,000 AND FAILURE MILEAGE WAS 7,800.

NHTSA ODI #10197082

Mileage unknown · Aug 2, 2005
Engine And Engine Cooling

DT: CONSUMER OWNED A 2004 VOLVO S60. ON GOING SINCE APRIL OF 2005 ENGINE REBUILT DUE TO STALLING. VEHICLE STALLED IN TRAFFIC AND DID NOT ACCELERATE PROPERLY. ALSO, VEHICLE SLOWED DOWN AT ONCE FOR NO REASON. WHILE DRIVING AFTER THE ENGINE WAS REBUILT AND WAS MERGING ONTO I87 NORTH AND VEHICLE STALLED. CONSUMER PULLED OFF T…

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DT: CONSUMER OWNED A 2004 VOLVO S60. ON GOING SINCE APRIL OF 2005 ENGINE REBUILT DUE TO STALLING. VEHICLE STALLED IN TRAFFIC AND DID NOT ACCELERATE PROPERLY. ALSO, VEHICLE SLOWED DOWN AT ONCE FOR NO REASON. WHILE DRIVING AFTER THE ENGINE WAS REBUILT AND WAS MERGING ONTO I87 NORTH AND VEHICLE STALLED. CONSUMER PULLED OFF THE RAMP ONTO THE SHOULDER. THEN PAUSED FOR ABOUT FIVE MINUTES TO REGAIN COMPOSURE AND THEN RESTARTED ENGINE. VEHICLE RESTARTED WITH NO PROBLEM. CONSUMER SAID THAT STALL ONLY HAPPENED TWICE. DEALER REPLACED MASS AIRFLOW SENSOR, BUT VEHICLE STILL DID NOT OPERATE CORRECTLY. CONSUMER THOUGHT THAT VEHICLE DID NOT OPERATE PROPERLY BETWEEN 2000 AND 3000 RPMS. THE MANUFACTURER SHOULD DO SOMETHING ABOUT THIS PROBLEM WHICH WAS VERY DANGEROUS. CONSUMER WORRIED ABOUT HER LIFE WHILE DRIVING VEHICLE.*AK

NHTSA ODI #10131117

Official recalls

5

21V766000 · Air Bags:frontal:driver Side:inflator Module

Sep 30, 2021

Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.

Consequence & remedy

Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.

Remedy: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10125.

10V566000 · Equipment:electrical:navigational System(global Positioning System)

Nov 8, 2010

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

Consequence & remedy

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 OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.

09V483000 · Fuel System, Gasoline:delivery:fuel Pump

Dec 18, 2009

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 CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. WHEN EXPOSED TO CERTAIN ENVIRONMENTAL CONDITIONS (HOT CLIMATE AND TEMPERATURE CYCLING) OVER TIME AND IN COMBINATION WITH VARYING FUEL QUALITY, THE FUEL PUMP CAN DEVELOP CRACKS IN THE FUEL PUMP FLANGE.

Consequence & remedy

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.

07V226000 · Engine And Engine Cooling

Jun 5, 2007

ON CERTAIN PASSENGER VEHICLES, THE FUEL PRESSURE SENSOR LOCATED ON THE LEFT END OF THE FUEL RAIL MAY, AT TIMES, TRANSMIT INCORRECT SIGNAL REGARDING THE FUEL PRESSURE TO THE ENGINE CONTROL MODULE. IF THE SIGNAL IS OUTSIDE OF THE PRE-PROGRAMMED ALLOWABLE LIMITS, A DIAGNOSTIC TROUBLE CODE MAY BE SET AND THE CHECK ENGINE LIGHT WILL COME ON. THE SOLDERED JOINTS ON THE CIRCUIT BOARD OF THE FUEL PRESSURE SENSOR MAY CRACK DUE TO TEMPERATURE CHANGES AND EXCESSIVE VIBRATIONS.

Consequence & remedy

Consequence: MISFIRE MAY OCCUR DURING DRIVING THAT, IN TURN, WILL REDUCE THE ENGINE TORQUE AND IN THE WORST CASE SCENARIO, THE ENGINE MAY STALL WITHOUT WARNING. IN CERTAIN TRAFFIC SITUATIONS THIS COULD CAUSE AN UNSAFE SITUATION AND POSSIBLY A CRASH.

Remedy: DEALERS WILL REPLACE THE FUEL PRESSURE SENSOR FREE OF CHARGE. THE RECALL BEGAN ON JUNE 29, 2007. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

04V029000 · Steering:linkages

Jan 16, 2004

ON CERTAIN PASSENGER VEHICLES, THE FRONT CONTROL ARMS MAY NOT HAVE BEEN MANUFACTURED CORRECTLY AND, AS A RESULT, THE STUD AND NUT THAT SECURE THE ARM TO THE SPINDLE MAY LOSE THEIR INITIAL AXIAL TENSION. UNDER CERTAIN DRIVING CONDITIONS, THE STEERING MAY BECOME LESS RESPONSIVE AND THE DRIVER MAY EXPERIENCE STEERING WHEEL PLAY.

Consequence & remedy

Consequence: THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL INSTALL A NEW TYPE OF NUT. OWNER NOTIFICATION BEGAN ON FEBRUARY 16, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

0

No exact-year investigations in this snapshot.