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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.

About this comparison →

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

What owners actually said

198 reports
65,983 miles · Feb 7, 2011
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING, THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE FAILURE WAS CAUSED BY THE FUEL PRESSURE SENSOR. THE CONTACT REFERENCED RECALL 07V226000 (ENGINE AND ENGINE COOLING) BUT WAS INFORMED BY THE MANUFACTURE…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING, THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE FAILURE WAS CAUSED BY THE FUEL PRESSURE SENSOR. THE CONTACT REFERENCED RECALL 07V226000 (ENGINE AND ENGINE COOLING) BUT WAS INFORMED BY THE MANUFACTURER THAT THE VEHICLE WAS NOT INCLUDED. THE CURRENT AND FAILURE MILEAGES WERE 65,983.

NHTSA ODI #10380936

70,000 miles · Feb 5, 2011
Engine And Engine Cooling

I DRIVE A VOLVO S60R AND WHEN I AM ACCELERATING I NOTICE THAT I HAVE A VERY LARGE LACK OF POWER GOING FROM 3000 TO 3500 RPM'S, THERE IS ALMOST NO INCREASE IN POWER. I HAVE BROUGHT UP THE ISSUE WITH A VOLVO DEALER AND THEY INFORMED ME THAT THERE WAS A RECALL FOR THIS, BUT MY CAR FOR SOME REASON DID NOT GET THE RECALL. HE SAID I…

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I DRIVE A VOLVO S60R AND WHEN I AM ACCELERATING I NOTICE THAT I HAVE A VERY LARGE LACK OF POWER GOING FROM 3000 TO 3500 RPM'S, THERE IS ALMOST NO INCREASE IN POWER. I HAVE BROUGHT UP THE ISSUE WITH A VOLVO DEALER AND THEY INFORMED ME THAT THERE WAS A RECALL FOR THIS, BUT MY CAR FOR SOME REASON DID NOT GET THE RECALL. HE SAID IT IS THE SAME ISSUE BUT THERE WAS NOTHING HE CAN DO ABOUT IT. *TR

NHTSA ODI #10380825

70,000 miles · Feb 5, 2011
Suspension

WHEN I DRIVE MY MANUAL TRANSMISSION S60R VOLVO, AND I SHIFT I HEAR A LOUD THUD IN THE BACK OF THE CAR, I CHECKED EVERYTHING THAT COULD POSSIBLY BE MAKING THE NOISE AND SECURED IT, IT BOTHERED ME SO MUCH I TOOK IT TO THE VOLVO DEALER AND THEY TOLD ME THAT IT WAS ACTUALLY BECAUSE OF THE SUSPENSION SOFTWARE AND THAT THERE WAS A RE…

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WHEN I DRIVE MY MANUAL TRANSMISSION S60R VOLVO, AND I SHIFT I HEAR A LOUD THUD IN THE BACK OF THE CAR, I CHECKED EVERYTHING THAT COULD POSSIBLY BE MAKING THE NOISE AND SECURED IT, IT BOTHERED ME SO MUCH I TOOK IT TO THE VOLVO DEALER AND THEY TOLD ME THAT IT WAS ACTUALLY BECAUSE OF THE SUSPENSION SOFTWARE AND THAT THERE WAS A RECALL FOR THIS, HOWEVER IT WAS NOT APPLICABLE FOR MY VIN. HE SAID THIS WAS THE BEST GUESS HE COULD MAKE, I INFORMED HIM THAT IT ONLY MAKES THE NOISE IF YOU MAKE A PRETTY GENTAL SHIFT, BUT IT CAN HAPPEN AT ANY TIME. *TR

NHTSA ODI #10380824

80,000 miles · Feb 5, 2011
Engine And Engine Cooling

WHEN I DRIVE MY MANUAL TRANSMISSION S60R VOLVO, AND I SHIFT I HEAR A LOUD THUD IN THE BACK OF THE CAR, I CHECKED EVERYTHING THAT COULD POSSIBLY BE MAKING THE NOISE AND SECURED IT, IT BOTHERED ME SO MUCH I TOOK IT TO THE VOLVO DEALER AND THEY TOLD ME THAT IT WAS ACTUALLY BECAUSE OF THE SUSPENSION SOFTWARE AND THAT THERE WAS A RE…

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WHEN I DRIVE MY MANUAL TRANSMISSION S60R VOLVO, AND I SHIFT I HEAR A LOUD THUD IN THE BACK OF THE CAR, I CHECKED EVERYTHING THAT COULD POSSIBLY BE MAKING THE NOISE AND SECURED IT, IT BOTHERED ME SO MUCH I TOOK IT TO THE VOLVO DEALER AND THEY TOLD ME THAT IT WAS ACTUALLY BECAUSE OF THE SUSPENSION SOFTWARE AND THAT THERE WAS A RECALL FOR THIS, HOWEVER IT WAS NOT APPLICABLE FOR MY VIN. HE SAID THIS WAS THE BEST GUESS HE COULD MAKE, I INFORMED HIM THAT IT ONLY MAKES THE NOISE IF YOU MAKE A PRETTY GENTLE SHIFT, BUT IT CAN HAPPEN AT ANY TIME. *TR

NHTSA ODI #10380823

72,000 miles · Jan 24, 2011
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED. AFTER THE FAILURE, ALL THE WARNING LIGHTS ILLUMINATED ON THE INSTRUMENTAL PANEL. THE VEHICLE WAS ABLE TO RESTART AFTER A COUPLE OF MINUTES OF WAITING. THE VEHICLE HAD NOT BEEN INSPECTED NOR HAD IT BEEN REP…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED. AFTER THE FAILURE, ALL THE WARNING LIGHTS ILLUMINATED ON THE INSTRUMENTAL PANEL. THE VEHICLE WAS ABLE TO RESTART AFTER A COUPLE OF MINUTES OF WAITING. THE VEHICLE HAD NOT BEEN INSPECTED NOR HAD IT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 72,000. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10378409

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

75,000 miles · Jan 13, 2011
Engine And Engine CoolingFuel System, Gasoline

THE ENGINE LIGHT CAME ON IN MY 2004 VOLVO S60R. THE CAR WOULD LOOSE ACCELERATION AND ALSO STALLED. VOLVO SAID IT WAS THE FUEL PRESSURE SENSOR AND THAT IT HAD BEEN RECALLED BY VOLVO- RECALL # 07V226000. BUT THE VIN # OF MY CAR WAS NOT INCLUDED IN THE RECALL. IT WAS THE SAME PART THAT WAS RECALLED ON OTHER 2004 S60S. WHY NOT ON TH…

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THE ENGINE LIGHT CAME ON IN MY 2004 VOLVO S60R. THE CAR WOULD LOOSE ACCELERATION AND ALSO STALLED. VOLVO SAID IT WAS THE FUEL PRESSURE SENSOR AND THAT IT HAD BEEN RECALLED BY VOLVO- RECALL # 07V226000. BUT THE VIN # OF MY CAR WAS NOT INCLUDED IN THE RECALL. IT WAS THE SAME PART THAT WAS RECALLED ON OTHER 2004 S60S. WHY NOT ON THE R AS WELL? *TR

NHTSA ODI #10376516

79,000 miles · Jan 13, 2011
Electrical SystemFire

VOLVO S60R SEAT ISSUE. TURNED SEAT HEATER ON, FELT VERY WARM SENSATION ON MY LEFT HIP/LEG AFTER A FEW MINUTES. TURNED SEAT HEATER OFF AND GOT OUT OF CAR TO CHECK WHAT WAS HAPPENING. SEAT HEATER BURNED THROUGH THE LEATHER AND ALSO MY JEANS. IS THERE A RECALL/FIX? SEEMS EXTREMELY DANGEROUS. *TR

NHTSA ODI #10376515

34,493 miles · Jan 11, 2011
Fuel System, Gasoline

TOOK VEHICLE TO A VOLVO DEALERSHIP FOR A REGULARLY SCHEDULED OIL CHANGE. THE SERVICE ADVISOR REPORTED THAT THE FUEL PRESSURE SENSOR (FPS) IS A CRITICAL COMPONENT, THAT IT FAILED AND NEEDED TO BE REPLACED. HE SAID THAT VOLVO WOULD PAY 50% FOR THE PART AND CHARGE ME THE WARRANTY LABOR RATE. THEY WOULD NOT TELL ME IN ADVANCE THE …

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TOOK VEHICLE TO A VOLVO DEALERSHIP FOR A REGULARLY SCHEDULED OIL CHANGE. THE SERVICE ADVISOR REPORTED THAT THE FUEL PRESSURE SENSOR (FPS) IS A CRITICAL COMPONENT, THAT IT FAILED AND NEEDED TO BE REPLACED. HE SAID THAT VOLVO WOULD PAY 50% FOR THE PART AND CHARGE ME THE WARRANTY LABOR RATE. THEY WOULD NOT TELL ME IN ADVANCE THE TOTAL COST. AS I WAS LEAVING, ANOTHER SERVICE ADVISOR TOLD A PERSON OVER THE TELEPHONE THEY NEEDED A FUEL PRESSURE SENSOR AND WOULD GET 50% OFF. A FEW DAYS LATER A FRIEND TOOK HER S40 TO THIS DEALER AND WAS TOLD SHE NEEDED A FUEL PRESSURE SENSOR TO FIX HER ACTUAL FUEL SYSTEM PROBLEM (IT DID NOT). THE ODDS OF A PERSON LEARNING ABOUT 3 VOLVOS NEEDING FUEL PRESSURE SENSOR REPLACEMENTS IN THIS MANNER SEEMS PHENOMENAL. AS SUCH, IT APPEARS THAT EITHER: 1) VOLVO'S FUEL PRESSURE SENSORS HAVE A HIGH FAULT RATE; 2) VOLVO UNDERSTATED THE CARS TO INCLUDE IN ITS RECALL CAMPAIGN NUMBER R181; 3) CARS INCLUDED IN THE RECALL CAMPAIGN ARE BEING CHARGED FOR THE REPAIR; OR 4) THE QUESTION OF HOW VOLVO IS / IS NOT MANAGING THE DEALER TO DETERMINE IF THERE IS A HIGH INCIDENCE OF FUEL PRESSURE SENSOR FAILURES ON THE CARS BEING SERVICED DURING THAT TIME PERIOD AND THE REASONS FOR THOSE FAILED FUEL PRESSURE SENSORS. NHTSA SHOULD REQUIRE VOLVO TO SUPPLY STATISTICS AND RECORDS (PROBABLY A SIMPLE VOLVO DATABASE SEARCH) FOR ALL VEHICLES RECEIVING NEW FUEL PRESSURE SENSORS AND IDENTIFY WHETHER: 1) THE REPAIR WAS INCLUDED IN RECALL NUMBER R181; 2) THE NON-RECALL FPS CUSTOMER WAS CHARGED FOR THE REPAIR; 3) THE NON-RECALL FPS CUSTOMER WAS NOT CHARGED FOR THE REPAIR. AND, FOR THOSE VEHICLES, THE NHTSA SHOULD REQUIRE VOLVO TO PROVIDE THE PLANT, PRODUCTION DATE, AND CHASSIS NUMBER. RUNNING THE REPORT IN MODEL NUMBER AND CHASSIS NUMBER ORDER (CHRONOLOGICAL ORDER) OF ALL CARS WITH FPS PROBLEM WOULD LIKELY AID THE NHTSA IN DETERMINING WHETHER THE EXTENT OF THE FPS PROBLEM AND ACCURACY OF THE VOLVO'S RECALL CAMPAIGN NUMBER R181. *TR

NHTSA ODI #10375581

96,000 miles · Dec 21, 2010
Vehicle Speed Control

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING AT ANY SPEED, THE CONTACT STATED THAT THE VEHICLE WOULD MOVE INTO LIMP MODE, CAUSING THE VEHICLE TO STALL. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. THE CONTACT DID NOT INFORM THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATE…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING AT ANY SPEED, THE CONTACT STATED THAT THE VEHICLE WOULD MOVE INTO LIMP MODE, CAUSING THE VEHICLE TO STALL. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. THE CONTACT DID NOT INFORM THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 96,000.

NHTSA ODI #10371941

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.