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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
64,450 miles · Apr 17, 2009
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 10 MPH, THE VEHICLE BEGAN TO DECELERATE AND THEN STALLED. THE ENGINE WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. FIVE MINUTES AFTER THE FAILURE OCCURRED, THE VEHICLE RESTARTED ITSELF. TWO DAYS LATER, THE VEHICLE WOULD NOT START. THE MANUFACTURER STATED T…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 10 MPH, THE VEHICLE BEGAN TO DECELERATE AND THEN STALLED. THE ENGINE WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. FIVE MINUTES AFTER THE FAILURE OCCURRED, THE VEHICLE RESTARTED ITSELF. TWO DAYS LATER, THE VEHICLE WOULD NOT START. THE MANUFACTURER STATED THAT THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN ID NUMBER 07V226000 (ENGINE AND ENGINE COOLING); THEREFORE, THEY WOULD NOT ASSUME ANY RESPONSIBILITY FOR THE REPAIRS. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 64,450.

NHTSA ODI #10265737

45,000 miles · Mar 19, 2009
Fuel System, Other

2004 VOLVO S60 FUEL PRESSURE SENSOR. VOLVO ISSUED A RECALL FOR THIS FOR 2003-2004 MODELS. MY CAR HAD THIS PROBLEM AND ITS SYMPTOMS (CAR STALLING). VOLVO DEALERSHIP SAID MY CAR DID NOT FALL INTO RECALL DUE TO VIN # BREAK. VOLVO CORPORATION NEVER BOTHERED TO RETURN MY CALLS. I FEEL THAT I SHOULD BE REIMBURSED FOR THIS REPAIR …

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2004 VOLVO S60 FUEL PRESSURE SENSOR. VOLVO ISSUED A RECALL FOR THIS FOR 2003-2004 MODELS. MY CAR HAD THIS PROBLEM AND ITS SYMPTOMS (CAR STALLING). VOLVO DEALERSHIP SAID MY CAR DID NOT FALL INTO RECALL DUE TO VIN # BREAK. VOLVO CORPORATION NEVER BOTHERED TO RETURN MY CALLS. I FEEL THAT I SHOULD BE REIMBURSED FOR THIS REPAIR AS IT CLEARLY MEETS THE RECALL DESCRIPTION. *TR

NHTSA ODI #10262478

Mileage unknown · Jan 15, 2009
Engine And Engine Cooling

2004 VOLVO S60 MAY HAVE A PRESSURE SENSOR PROBLEM. CONSUMER STATES THAT THERE IS NO VOLVO DEALER IN HER AREA AND NEEDS HELP WITH FINDING ONE. *NJ

NHTSA ODI #10255669

77,600 miles · Jan 15, 2009
Parking Brake

PARKING BRAKE PAD DELAMINATED FROM SHOE: DISLODGED AFTER DRIVING OVER A BUMP IN THE ROAD AND BECAME WEDGED INTO REAR SPINDLE CAUSING WHEEL TO LOCK UP AND RESULTED IN MAJOR DAMAGE TO BRAKE AND WHEEL COMPONENTS. 1 OCCURRENCE, REQUIRED REPLACEMENT OF LEFT REAR ROTOR, BACKING PLATE, SPINDLE, PARKING BRAKE SHOES (BOTH SIDES) AND PAR…

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PARKING BRAKE PAD DELAMINATED FROM SHOE: DISLODGED AFTER DRIVING OVER A BUMP IN THE ROAD AND BECAME WEDGED INTO REAR SPINDLE CAUSING WHEEL TO LOCK UP AND RESULTED IN MAJOR DAMAGE TO BRAKE AND WHEEL COMPONENTS. 1 OCCURRENCE, REQUIRED REPLACEMENT OF LEFT REAR ROTOR, BACKING PLATE, SPINDLE, PARKING BRAKE SHOES (BOTH SIDES) AND PARKING BRAKE CABLE. *TR

NHTSA ODI #10255132

80,550 miles · Jan 6, 2009
Engine And Engine Cooling

2004 VOLVO S60 ENGINE STALLS WITHOUT WARNING, ERROR CODE OF "FUEL PRESSURE SENSOR" INDICATED BY CHECK ENGINE LIGHT/ONBOARD DIAGNOSTICS. EXACT SAME PROBLEM IS ALREADY PART OF NHTSA RECALL BULLETIN REFERENCE NUMBER(S): 07V226000 HOWEVER, NOT ALL 2004 S60 VIN'S ARE BEING COVERED. THIS IS AN EXTREMELY DANGEROUS SITUATI…

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2004 VOLVO S60 ENGINE STALLS WITHOUT WARNING, ERROR CODE OF "FUEL PRESSURE SENSOR" INDICATED BY CHECK ENGINE LIGHT/ONBOARD DIAGNOSTICS. EXACT SAME PROBLEM IS ALREADY PART OF NHTSA RECALL BULLETIN REFERENCE NUMBER(S): 07V226000 HOWEVER, NOT ALL 2004 S60 VIN'S ARE BEING COVERED. THIS IS AN EXTREMELY DANGEROUS SITUATION! SUDDEN LOSS OF ENGINE POWER/STALLING AT HIGHWAY SPEEDS COULD EASILY RESULT IN A FATAL ACCIDENT FOR PASSENGERS AND OTHER MOTORISTS. VOLVO NEEDS TO EXPAND THE RECALL/BULLETIN TO INCLUDE ALL 2004 VOLVO S60 MODELS! *TR

NHTSA ODI #10253930

92,000 miles · Jan 2, 2009
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING LESS THAN 50 MPH AND SLOWING DOWN TO MAKE A TURN, THE VEHICLE STALLED. THIS BECAME A PATTERN WHEN ATTEMPTING TO MAKE LEFT AND RIGHT TURNS. THE DEALER STATED THAT THERE WAS A RECALL FOR THE FAILURE; HOWEVER, HIS VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 07V226000 (ENGI…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING LESS THAN 50 MPH AND SLOWING DOWN TO MAKE A TURN, THE VEHICLE STALLED. THIS BECAME A PATTERN WHEN ATTEMPTING TO MAKE LEFT AND RIGHT TURNS. THE DEALER STATED THAT THERE WAS A RECALL FOR THE FAILURE; HOWEVER, HIS VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER 07V226000 (ENGINE AND ENGINE COOLING). NO REPAIRS HAVE BEEN MADE TO DATE. THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE LESS THAN 92,000.

NHTSA ODI #10253603

55,000 miles · Oct 28, 2008
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE VEHICLE WOULD SPORADICALLY STALL WITHOUT WARNING. SPEED WAS NOT A FACTOR DURING THE FAILURES. A MECHANIC INSPECTED THE VEHICLE, BUT THE CAUSE OF THE FAILURE COULD NOT BE DETERMINED. THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN ID NUMBER 07V226000 (ENGINE AND ENGIN…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE VEHICLE WOULD SPORADICALLY STALL WITHOUT WARNING. SPEED WAS NOT A FACTOR DURING THE FAILURES. A MECHANIC INSPECTED THE VEHICLE, BUT THE CAUSE OF THE FAILURE COULD NOT BE DETERMINED. THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN ID NUMBER 07V226000 (ENGINE AND ENGINE COOLING). AS OF OCTOBER 28, 2008, THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 55,000 AND CURRENT MILEAGE WAS 58,888. UPDATED 12-02-08 *BF UPDATED 12/02/08. *JB

NHTSA ODI #10246979

25,000 miles · Oct 24, 2008
Power Train

ANGLE GEAR FAILURE IN VOLVO S60R AWD. *TR

NHTSA ODI #10246583

62,000 miles · Oct 2, 2008
Electrical System

DRIVING ALONG THE HIGHWAY AT BOUT 70 MPH, THE CAR SUDDENLY HESITATES AND LOSES POWER (THE RPM READER, AND SPEEDOMETER FALL TO 0). THE CAR THEN REGAINS POWER AND THEN IT JERKS AND HESITATES, ONCE AGAIN LOSING POWER. THIS TIME THE POWER STAYS OUT. HAVEN'T HAD THE PROBLEM FIXED YET THE INITIAL ACCELERATION OF THE CAR IS EXTREM…

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DRIVING ALONG THE HIGHWAY AT BOUT 70 MPH, THE CAR SUDDENLY HESITATES AND LOSES POWER (THE RPM READER, AND SPEEDOMETER FALL TO 0). THE CAR THEN REGAINS POWER AND THEN IT JERKS AND HESITATES, ONCE AGAIN LOSING POWER. THIS TIME THE POWER STAYS OUT. HAVEN'T HAD THE PROBLEM FIXED YET THE INITIAL ACCELERATION OF THE CAR IS EXTREMELY SLOW AND IT REQUIRES A HARD PRESS ON THE GAS TO GET THE CAR IN MOTION. THE POWER DOESN'T WORK FOR THE FOLLOWING FUNCTIONS: POWER LOCK (INCLUDING THE REMOTE) ALL STEERING WHEEL FUNCTIONS (RADIO AND CRUISE CONTROL) HEADLIGHTS TURN SIGNALS WINDSHIELD WIPERS SUN ROOF SIDE AND REAR VIEW MIRRORS AIR CONDITIONING CONTROLS ALL GAUGES IN THE DASHBOARD. *TR

NHTSA ODI #10244245

91,000 miles · Oct 2, 2008
Engine And Engine CoolingFuel System, Gasoline

TL*THE CONTACT'S SPOUSE OWNS A 2004 VOLVO S60. ON APPROXIMATELY TWENTY OCCASIONS, THE VEHICLE WOULD COMPLETELY SHUT OFF AND NEED TO BE RESTARTED INTERMITTENTLY. THE FAILURE OCCURRED WHILE BRAKING OR TURNING THE VEHICLE. THE DEALER WAS ABLE TO DUPLICATE THE FAILURE, BUT COULD NOT GET AN ERROR CODE FROM THE DIAGNOSTIC MACHINE. R…

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TL*THE CONTACT'S SPOUSE OWNS A 2004 VOLVO S60. ON APPROXIMATELY TWENTY OCCASIONS, THE VEHICLE WOULD COMPLETELY SHUT OFF AND NEED TO BE RESTARTED INTERMITTENTLY. THE FAILURE OCCURRED WHILE BRAKING OR TURNING THE VEHICLE. THE DEALER WAS ABLE TO DUPLICATE THE FAILURE, BUT COULD NOT GET AN ERROR CODE FROM THE DIAGNOSTIC MACHINE. RECALL NUMBER 07V226000 IS REGARDING THE SAME ISSUE; HOWEVER, THE VIN IS NOT INCLUDED. THE CURRENT MILEAGE WAS 92,000 AND FAILURE MILEAGE WAS 91,000.

NHTSA ODI #10244189

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.