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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

Equipment complaints

4 reports
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111,000 miles · Jan 16, 2011
Equipment

2004 S60 VOLVO ALARM SYSTEM SERVICE REQUIRED. I'VE OWNED MORE THAN 8 DIFFERENT CARS OLDER THAN THIS CAR, AND THEY NEVER HAD ANY ISSUE WITH THE ALARM. IT SEEMS TO BE VERY COMMON TO REPLACE THE ALARM MODULE IN THIS VOLVO MODEL BECAUSE OF THE ACID LEAK FROM THE BATTERY THAT CAUSES A SHORT IN THE CIRCUIT. AND YES IT WILL HAPPEN AGAI…

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2004 S60 VOLVO ALARM SYSTEM SERVICE REQUIRED. I'VE OWNED MORE THAN 8 DIFFERENT CARS OLDER THAN THIS CAR, AND THEY NEVER HAD ANY ISSUE WITH THE ALARM. IT SEEMS TO BE VERY COMMON TO REPLACE THE ALARM MODULE IN THIS VOLVO MODEL BECAUSE OF THE ACID LEAK FROM THE BATTERY THAT CAUSES A SHORT IN THE CIRCUIT. AND YES IT WILL HAPPEN AGAIN AFTER THE REPLACEMENT. WHAT A RIPOFF. *LN

NHTSA ODI #10376877

159,000 miles · May 3, 2010
Equipment

I HAVE 2004 VOLVO S60VOLVO . I WAS TRYING TO RAISE MY VEHICLE ON THE OEM JACK CAME WITH MY CAR TO CHANGE THE WHEEL. AFTER FEW SECOND I REMOVED MY TIRE , THE JACK COLLAPSED - AND MY CAR CAME CRASHING DOWN. I WAS LUCKY AS I HAD STUCK MY HEAD INTO THE WHEEL WELL MOMENTS BEFORE TO CHECK MY BRAKE PADS AND ROTORS, AND HAD MY FINGERS A…

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I HAVE 2004 VOLVO S60VOLVO . I WAS TRYING TO RAISE MY VEHICLE ON THE OEM JACK CAME WITH MY CAR TO CHANGE THE WHEEL. AFTER FEW SECOND I REMOVED MY TIRE , THE JACK COLLAPSED - AND MY CAR CAME CRASHING DOWN. I WAS LUCKY AS I HAD STUCK MY HEAD INTO THE WHEEL WELL MOMENTS BEFORE TO CHECK MY BRAKE PADS AND ROTORS, AND HAD MY FINGERS AROUND THE SUSPENSION LINKAGES. *TR

NHTSA ODI #10328633

42,500 miles · Jul 21, 2008
EquipmentTires

LATE LAST SUMMER, UPON STARTING UP MY CAR, I NOTICED A HISSING NOISE COMING FROM THE CENTER PANEL ON THE DASHBOARD. DIDN'T REALLY THINK ANYTHING OF IT UNTIL I TRIED TO TURN ON THE AIR CONDITIONER AND THE CAR MADE THE SAME HISSING NOISE. NOISE LASTS ONLY 5-10 SECONDS UPON STARTUP OF THE CAR OR THE AC, BUT NOW THE AC ONLY BLOWS …

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LATE LAST SUMMER, UPON STARTING UP MY CAR, I NOTICED A HISSING NOISE COMING FROM THE CENTER PANEL ON THE DASHBOARD. DIDN'T REALLY THINK ANYTHING OF IT UNTIL I TRIED TO TURN ON THE AIR CONDITIONER AND THE CAR MADE THE SAME HISSING NOISE. NOISE LASTS ONLY 5-10 SECONDS UPON STARTUP OF THE CAR OR THE AC, BUT NOW THE AC ONLY BLOWS HOT AIR. TOOK CAR TO VOLVO DEALERSHIP HERE IN SOUTHERN CALIFORNIA WHERE I PURCHASED THE CAR AND THEY SAID THAT THEY WERE GOING TO HAVE TO RIP OPEN THE ENTIRE FRONT PANEL TO INVESTIGATE THE PROBLEM. AS I HAVE BEEN TOLD TWICE PREVIOUSLY BY THIS DEALERSHIP THAT I NEED SERVICE THAT I DID NOT REALLY NEED (THIS WAS NOW THE THIRD TIME), I CHOSE TO HOLD OFF ON LETTING THEM PERFORM SUCH A TASK. INSTEAD, I TOOK THE CAR TO ANOTHER MECHANIC AND DESCRIBED THE PROBLEM TO HIM. HE LET ME KNOW THAT WHEN THERE WAS NO FREON LEFT IN THE AC UNIT. THEY REPLACED IT AND WITHIN ONE DAY, IT HAD COMPLETELY LEAKED. THEY THEN PERFORMED AN INSPECTION ON THE AC AND EITHER THE COMPRESSOR OR THE HOSES HAS A MAJOR LEAK IN IT. I HAVE NO ACCIDENTS AND THE CAR HAS LESS THAN 60,000 MILES ON IT CURRENTLY. THE PROBLEM WAS FIRST DETECTED AT LESS THAN 45,000 MILES ON IT. ESTIMATE ON REPAIR WAS $1500+. AT 22,500 MILE CHECKUP, VOLVO REPLACED RADIATOR ON CAR. MECHANIC SAID THAT IT WAS POSSIBLE THAT VOLVO DEALERSHIP MAY HAVE DAMAGED THE AC UNIT AT THAT TIME SINCE THEY ARE IN CLOSE PROXIMITY. IN ADDITION, AS I NOTICED ON ANOTHER PERSON'S COMPLAINT FORM, I ALSO HAVE THE RUBBING OF THE FRONT TIRES WHEN TURNING. QUITE ANNOYING AND I DO MY BEST TO AVOID THE FRICTION AT ALL COSTS. DOESN'T OCCUR ON NORMAL TURNS, JUST WHEN MANEUVERING FOR PARKING SPACES OR GETTING OUT OF MY PARKING GARAGE. *TR

NHTSA ODI #10235108

70,000 miles · Jun 9, 2008
Engine And Engine CoolingEquipmentService Brakes, Hydraulic

2004 VOLVO S60 2.5T. PURCHASED THE CAR USED IN SEPT 07. 6-5-08 PANEL DISPLAYED OPEN REAR DOOR WHILE DRIVING 65MPH ON HIGHWAY, MY DOOR WAS NOT OPENED. CAR JERKED AS IF THERE WAS POWER LOSS, AC WENT OFF, BRAKE FAILURE LIGHT ON PANEL, POWER WINDOWS AND LOCKS DID NOT WORK, TEMP 105 , THEN DRIVER PANEL WENT BLACK. CAR JERKED 3 T…

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2004 VOLVO S60 2.5T. PURCHASED THE CAR USED IN SEPT 07. 6-5-08 PANEL DISPLAYED OPEN REAR DOOR WHILE DRIVING 65MPH ON HIGHWAY, MY DOOR WAS NOT OPENED. CAR JERKED AS IF THERE WAS POWER LOSS, AC WENT OFF, BRAKE FAILURE LIGHT ON PANEL, POWER WINDOWS AND LOCKS DID NOT WORK, TEMP 105 , THEN DRIVER PANEL WENT BLACK. CAR JERKED 3 TIMES IN MID TRAFFIC, I WAS SCARED TO DEATH FOR MY LIFE. ARRIVED AT MY EXIT, PULLED OVER TO A GAS STATION, ENGINE STILL RUNNING BUT SLUGGISH, RADIO WAS STILL ON, POWER DOOR LOCKS AND WINDOWS DID NOT WORK, AC OFF. ENGINE STILL RUNNING SO I MADE IT A COUPLE OF MILES UP THE STREET TO MY HOME. CUT THE CAR OFF AND BACK ON, ALL POWER RETURNED, NOW CHECK ENGINE AND AIR BAG TROUBLE ON PANEL. WENT TO VOLVO DEALER NEXT DAY 6-6-08 NEAR MY HOME, THEY CAN NOT SEE MY CAR TIL NEXT WEEK TUESDAY. WENT TO PEPBOYS, BATTERY AND ALTERNATOR ARE OK, CAN NOT ACCESS ENGINE BOX, MUST GO TO DEALER. CALLED VOLVO FOR TUESDAY 6-10-08 APPOINTMENT. CAR DUPLICATED SAME PROBLEM MONDAY 6-9-08 ON DRIVE HOME FROM WORK ON THE HIGHWAY TEMP 105 ETC. SEARCHED FOR COMPLAINTS AND RECALLS, MY RECALLS WERE REPORTED COMPLETED WHEN I PURCHASED THE CAR, FOUND ALL OF THIS VALUABLE INFO ONLINE, WILL SEE DEALER TOMORROW AND TAKE THESE RELATED COPIES OF COMPLAINTS WITH ME. *TR

NHTSA ODI #10230386

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.