- The problem
- Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
- The risk
- AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
- The fix
- 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.
Vehicle safety record
2004 Volvo S40 Problems, complaints & recalls
Owners have filed 50 complaints about the 2004 Volvo S40 with NHTSA, most often about the brakes (12) and the airbags (12). Those complaints describe 5 crashes, 1 fire and 4 injuries. It is covered by 6 recalls, the latest in November 2010 for the navigational system(global positioning system). For comparison, the 2003 has 21 and the 2005 has 81.
NHTSA data checked
DMore problems than a typical S40 year, for its age
#151 most complained-about 2004 vehicle
- Complaints
- 50
- Recalls
- 6
- Crashes
- 5
- Fires
- 1
- Injuries
- 4
- Deaths
- 0
Most common 2004 Volvo S40 problems
Share of all 50 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.
2004 Volvo S40 recalls 6
Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do
- The problem
- On certain vehicles sold in or currently registered in the states of connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia, reoccurring, long-term exposure to certain environmental conditions such as salty-wet conditions, it is possible for the pump electronic module (pem) to become corroded internally. This can cause a faulty signal to the fuel pump, resulting in low or no fuel pressure to the engine.
- The risk
- If this occurs, the check engine light may illuminate. In some cases, the vehicle may fail to start or may stall, increasing the risk of a crash.
- The fix
- Dealers will replace the pem and install it in a new location to prevent corrosion. The recall began on february 20, 2008. Owners may contact volvo at 1-800-458-1552.
- The problem
- On certain passenger vehicles equipped with t5 turbo engines, the polyamide tube in the fuel line is sensitive to the extreme temperatures that may occur in the area where the turbo/exhaust manifold is located.
- The risk
- This may potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
- The fix
- Dealers will change the fuel line material to teflon free of charge. The recall began on june 5, 2006. Owners may contact volvo cars at 1-800-458-1552.
- The problem
- On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
- The risk
- If this occurs, more brake pedal force may be required to stop the vehicle and/or may experience a rough engine idle, which could result in a crash.
- The fix
- Dealers will inspect, and if necessary, replace the vacuum hose. The recall began on november 29, 2004. Owners should contact volvo cars at 1-800-458-1552.
- The problem
- On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
- The risk
- Fuel leakage in the presence of an ignition source could result in a fire.
- The fix
- Dealers will install a v-clamp to the fuel rail. Owner notification began on january 28, 2004. Owners should contact volvo at 1-800-458-1552.
- The problem
- Certain passenger cars fail to comply with the requirements of federal motor vehicle safety standard no. 225, "Child restraint anchorage systems." The second isofix guide was not installed in these vehicles and, in certain cases, the owner's manual isofix information is incorrect.
- The risk
- This does not meet the requirements of the standard.
- The fix
- Owners will receive a letter/package consisting of the second isofix guide with installation instructions, and in certain cases, the corrected owner's manual may be provided. If the owner wants to take their vehicle to a volvo dealer for installation of the guide, it will be performed at no charge to the owner. Owner notification began on december 19, 2003. Owners should contact volvo at 1-800-458-1552.
What owners say
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50 complaints about the 2004 Volvo S40
Newest first, as filed with NHTSA by owners. Page 1 of 2.
Having a coolant leakage, crash mode and safety alarm system check keeps coming on...When crash mode comes on...Car just shuts off.
Tl* the contact owns a 2004 volvo s40 equipped with cooper zeon rs3-a tires, size: 205/55/16r (na). The contact heard a loud humming noise coming from the tires. The inside of the tread had a line and the contact noticed damage or an opening. An independent mechanic confirmed that the tires were separating at the tread line. An unknown tire dealer stated that the tires were not under warranty after the tires had been owned for over three years. The manufacturer was notified. The vehicle failure mileage was 145,000. The tire failure mileage and vin were unknown.
No collision. Srs light has been coming on since 2007. Dealership has replaced wiring, air bags and nothing helps. Srs light comes on every 7 to 12 months. This has been going on for 11 years.
The key does not turn all the way to turn the ignition - it's locked after turning I and ii (not to iii). I had to have the car towed. I could have been stranded in an unsafe area. I called volvo customer service, but I was told it's not under warranty anymore. I went to youtube as to how I could fix it and found out quite a fee s40 owners have similar problems. I was told that the cost to fix this would run about $1000. I found a way to get around making it work by removing the steering cover, pull the...
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ignition switch with a screw driver. Without the key on the ignition, it still poses a safety issues because what if the steering locks while I am driving? Another issue is the suspension: the car feel as if it's falling apart. Twice we spent over a thousand for each occurrence. I'm quite certain there have a few complaints on similar issues. I would appreciate it very much if you could keep me in the loop if issues come up on this make, model and year we still own and keep on driving. I almost forgot, one of the head lights does not and even simple replacing with one after a bulb, still does not work. I guess it needs a trip to the dealership for them to figure it out. After all, sudden headlight failure while driving at night, is a serious safety issue. Thank you in advance for considering to take my issues.
The issue of no headlights (low-bulb failure) is dangerous & expensive. Nor is there a viable permanent repair as the "low-bulb failure" always re-occurs & has been an ongoing problem for me since my car was new. Suddenly having no headlights causes a serious & immediate safety issue for occupants of the car & for oncoming traffic who can't see a car without headlights. It can be 1 headlight or both that fail without warning; leaving no time to bring a vehicle to a stop safely. The experience is frightening &...
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dangerous in those tense moments it takes to stop a moving car on the road without headlights. I have even been issued a violation ticket from the police for equipment failure despite numerous repair bills that I keep in the car. After repeated attempts at getting volvo to fix this issue, I reported the problem to nhtsa several years ago but was told there had not been enough complaints about the headlight failure problem to do anything. Now, years have gone by and I am still dealing with a car that is essentially a daytime only car as it is not safe to drive after dark due to the unpredictable loss of headlights. Each time the headlights fail I bring the car for service and every time the headlight fails again and again within weeks of the "repair". Repair cost are in the $500 range. There is no recourse for the repairs other than to try something new. It has become a problem that is widely known at repair shops; and aftermarket repair kits are now common because volvo has ignored the issue stating that there is not a problem to me. It is easy to find many car owners with the same issue and frustrations on the internet as well as suits brought against other auto manufacturers for the wide-scale failure of these useless, defective headlights. Nhtsa should prohibit these headlights and force action for those responsible to address this known safety issue. *Tr
Brake pedal is too close to accelerator pedal. Whenever I operate the gas pedal, the side of my shoe also activates the brake. The problem is aggravated by the center tunnel carpet intruding on the minimal accelerator pedal space.
My vehicle doors lock up and can't be unlocked due to faulty locks. No way to get door or doors to unlock. Which can cause death if involved in a roll over, submerged, or any major accidents. It can be any door on the vehicle. On mine it's my rear passenger door which my child sits next too in her car seat. I've read many other volvos have this issue and very costly to repair. Volvo should be responsible as I have been told by a volvo dealer mechanic that these s40 are very known to have this issue. For my...
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experience of this happening is just driving home and parking. Tried to get my daughter out and it would not unlock. The key faubourg, the power lock switch and tried pulling on handle and nothing unlocks this door. I read that the lock actuators are the cause or its the wiring harness. I also have this problem in the trunk. Only the kid napped cord works to get the trunk to open. Please get volvo to fix all there actuators before kids or adults get trapped and killed cause of their negligence
Car is stalling out while driving down the road engine light came on when put on machine error given is fuel pressure. The fuel pressure was checked and was at correct pressure for the car. I have replaced fuel censer and car ran fine for 2 days then same issue with same error the fuel controller has a corroded pen I tried to call volvo they are telling me there is nothing they can do when I can clearly see the year make and model have had a recall for the exact issue that I am having with this car. The recall...
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number in your system is 08v033000 I normally would just get the car fixed but this is a major issue it seems the location of the controller needs to be moved to prevent this from happening again. This is a car my 16 year old daughter drives so you can understand my concern with vovlo not wanting to correct this
I got new car in nov 2003 of the year 2004 model. It feels like one has to put foot on brakes all the way to apply. It is progressively getting worse. In dec 2005, while existing from highway we meet an accident as it did not stop where it was suppose to stop. Volvo dealer top the break fluid during maintenance. But did not solve the problem. We got new brake pads from volvo dealer and changed along with brake discs in 2009. But, it did not solve the problem. In the morning, it will not break unless one has to put...
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foot on pedal few times. Again in 2015 we got brake pads from other auto part shop of high quality but it does not solve the problem. In addition, I smell gas but could not locate any leak of fuel. Also, steering wheel is very hard and we took to volvo few times but it is the same.
Tl* the contact owns a 2004 volvo s40. The contact stated that the accelerator pedal and the brake pedal became difficult to depress. Also, the contact mentioned that due to the proximity of the pedals, the brake pedal was inadvertently depressed when applying the accelerator pedal. The vehicle was not diagnosed. The manufacturer was notified of the failure. The failure mileage was not available.
Tl* the contact owns a 2004 volvo s40. While driving at approximately 10 mph, the vehicle stalled without warning. The vehicle did not restart. The vehicle was taken to a dealer where it was diagnosed that the pem was faulty. The vehicle was repaired. The manufacturer was made aware of the issue. The failure mileage was 100,625. Updated 04/07/15*lj updated 11/3/2015*js
I just brought the car from jcl auto sales in allentown pa at the end of august and my check engine continues to come on. *Tr
For the past two mornings my car has no brakes when I first start my car, once I have been driving for a few minutes it's okay, but first thing the past two mornings I haven't had brakes! *Tr
Tl* the contact owns a 2004 volvo s40. The contact stated that while driving 55 mph, the engine stalled. The check engine and battery indicators illuminated when the failure occurred, and the vehicle veered to the right. The contact pulled the vehicle to the side of the road. The vehicle would not restart and was towed to the contact's residence. The failure occurred twice. The manufacturer was not notified and advised that the vin was not included in nhtsa campaign id number: 08v033000 (fuel system,...
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gasoline). A diagnostic test indicated that the fuel pump module needed to be replaced. The vehicle was repaired and the failure did not recur. The failure mileage was 118,600. ..Updated 08/11/14 *bf the vehicle was repaired at the owner's expense. Updated 08/21/2014 *js
Tl* the contact owns a 2004 volvo s40. The contact stated that the air bag warning light illuminated without warning. The dealer was contacted and advised him that the occupant weight sensor may have failed and needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and they offered him a 10 percent coupon. The failure mileage was approximately 95,000. The current mileage was approximately 110,000.
First occurrence about 87000 miles was traveling on freeway when car stalled. Started it back up and check engine light came on. Took vehicle to dealer and they installed new spark plug and wires. Stalled again at about 89000 miles and was told to bring back when check engine light came back on. Check engine light came on again and took vehicle in on saturday but store was remodeling and couldn't get me in. Took car in for 90000 mile service and check engine light was on. Was told that spark plugs were installed....
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I informed them I had spark plugs and wires installed the last service and that this stalling of my vehicle is dangerous. Was told that after the spark plugs were installed it cleared the check engine light and that I would have to bring the car in again when the check engine light was on. Dealership has been of no help with this issue. Looked online for people with similar problems and it points to recall #08v033000. *Js
Tl* the contact owns a 2004 volvo s40. The contact stated that the driver side air bags were previously replaced under warranty due to the warning light illuminating continuously. The vehicle was taken to the dealer for routine maintenance but the dealer informed him that the air bags needed to be replaced. The contact attempted to contact the manufacturer to no avail. The vehicle was not repaired. The vin was unavailable. The failure mileage was 89,000.
Tl* the contact owns a 2004 volvo s40. While the contact started the ignition, the air bag warning indicator began to illuminate continuously until the engine was turned off. The vehicle was taken to an authorized dealer, where the front driver's side air bag was replaced. One year later, after the repair was performed the failure recurred. The air bag was replaced for a second time. The manufacturer was notified of the failure. The approximate failure mileage was 89,000.
Tl* the contact owns a 2004 volvo s40. The contact stated that he experienced a significant increase in stopping distance while braking on three occasions. The vehicle was not taken to have the failure diagnosed or repaired. The manufacturer was made aware of the failure and the contact was informed that the vehicle was not included in the recall associated with nhtsa campaign id number 04v493000 (service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings). The failure mileage was 6,000.
Tl* the contact owns a 2004 volvo s40. The contact stated the floor behind the drivers side seat was soaking wet. The dealer was contacted and advised him that the water was entering the vehicle from the drainage on the sunroof. The manufacturer was contacted and offered no assistance. The vehicle was not repaired. The failure and current mileage was approximately 97,000. The vin was unavailable.
The steering locked on our 2004.5 Volvo s40 t5 as my wife and 6 week old daughter were backing out of our driveway under power. No errors were reported when the car started, but the wheel locked (and an error was displayed) after the car was in motion. She stopped the vehicle when she was unable to turn the wheel. She was then able to put the car into drive and move back to her previous position. Clearly a safety sensor did not do its job. Leading up to this event we have had occasional incidents where the...
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steering wheel would not unlock after entering the key. Lightly moving the wheel side to side and repeated key entries would resolve the issue. A motor now runs in the steering column when trying to unlock the wheel. This is a different sound then we experienced when the issue could be resolved. I am very concerned about this incident because the lockup occurred while the vehicle was in motion. This could have resulted in a potentially fatal crash had it occurred on a sharp turn or on the freeway. Please investigate this critical safety issue. I have a video of the issue available if this will assist your investigation. *Tr
Tl*the contact owns a 2004 volvo s40. While driving approximately 30 mph, the contact stated that the check engine warning light illuminated when the vehicle suddenly stalled without warning. The failure was similar to nhtsa campaign id number: 08v033000 (fuel system, gasoline:delivery:fuel pump). The dealer refused to repair the defective component. The manufacturer informed the contact that they will only replace the component after it failed although the vehicle may stall while driving. The vehicle was taken...
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to a local mechanic who notified the contact that they needed to replace the fuel pump and performed the repairs; however, the repair did not correct the failure. The local mechanic stated that they needed to replace the pump electric module and the vehicle was awaiting repairs. The current mileage was 105,000 and the failure mileage was 95,000.
Tl* the contact owns a 2004 volvo s40. The contact stated that as the vehicle was started, the engine exhibited an abnormal increase in engine rpms up to 4000. The contact then shifted into drive and the vehicle abnormally accelerated to 40 mph. The contact stated that he drove home with the brakes depressed as the vehicle continued to move forward. When he arrived home, he abruptly jammed down on the brake pedal and shifted to park until the vehicle came to a stop. The manufacturer was contacted and advised that...
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the failure could be caused by a defect in the throttle cable. The contact inspected the throttle cable and discovered that the spring was melted causing the throttle to remain open and the vehicle to accelerate. The dealer was contacted and was awaiting the arrival of the necessary parts to make repairs. The failure mileage was 85,000 and the current mileage was 130,000. Updated 06/03/11 *bf the throttle cable was coming apart. Updated 08/08/11
Srs warning light on defective occupant weight sensor. *Tr
Volvo s40 t5 2004 is not accelerating properly. Rpms increase drastically and speed does not increase. The vehicle has stalled twice while driving along with traffic. Repairs related to similar symptoms: replaced and relocated pem in 2008, engine control module software was updated due to faulty software in 2008 same problems occurred a month ago and recurring at a more extreme level now. This faulty manufacturing does not include other problems that were fixed a few months ago while under warranty and now reappearing again. *Tr
Volvo S40: every year compared
All S40 years2004 Volvo S40 vs rivals
| Vehicle | Complaints | Recalls | Grade | |
|---|---|---|---|---|
| 2004 Volvo S40 | 50 | 6 | D | |
| 2004 Volvo S60 | 198 | 6 | F | Compare |
| 2004 Volvo V70 | 89 | 6 | F | Compare |
| 2004 Volvo S80 | 50 | 5 | D | Compare |
| 2004 Volvo C70 | 16 | 0 | C | Compare |
| 2004 Volvo VNL | 5 | 6 | C | Compare |
| 2004 Volvo 780 | 5 | 0 | C | Compare |
| 2004 Volvo V40 | 4 | 3 | C | Compare |
| 2004 Volvo VHD | 3 | 7 | C | Compare |
More sales usually means more complaints, so compare similar vehicles of the same year. The grade compares each vehicle with its own model's other years.
Questions about the 2004 Volvo S40
Does the 2004 Volvo S40 have any recalls?
Yes - NHTSA lists 6 recalls for the 2004 Volvo S40: navigational system(global positioning system) (November 2010); fuel pump (January 2008); fuel system, gasoline (April 2006); hoses, lines / piping, and fittings (October 2004) and more. Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.
What are the most common problems with the 2004 Volvo S40?
By the complaints owners filed with NHTSA, the most common problem areas are the brakes (12), airbags (12), electrical system (11).
How many complaints has the 2004 Volvo S40 had?
50 complaints have been filed with NHTSA, the first on October 19, 2004 and the latest on November 8, 2020. Of these, 5 describe a crash and 1 a fire, and together they report 4 injuries and 0 deaths.
Is the 2004 Volvo S40 a reliable vehicle?
Its Safety Index is 29 out of 100 (grade D: more problems than a typical Volvo S40 year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.
Which Volvo S40 years have the most complaints?
2000 (122), 2001 (84), 2005 (81). See every Volvo S40 year compared.
What should I do if my 2004 Volvo S40 has a problem?
If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data