- The problem
- 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.
- The risk
- An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
- The fix
- 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.
Vehicle safety record
2004 Volvo S60 Problems, complaints & recalls
Owners have filed 198 complaints about the 2004 Volvo S60 with NHTSA, most often about the engine & cooling (85) and the fuel system (55). Those complaints describe 12 crashes, 12 fires and 8 injuries. It is covered by 6 recalls, the latest in September 2021 for the inflator module. For comparison, the 2003 has 123 and the 2005 has 44.
NHTSA data checked
FFar more problems than a typical S60 year, for its age
#71 most complained-about 2004 vehicle
- Complaints
- 198
- Recalls
- 6
- Crashes
- 12
- Fires
- 12
- Injuries
- 8
- Deaths
- 0
Most common 2004 Volvo S60 problems
Share of all 198 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.
2004 Volvo S60 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
- 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.
- The problem
- 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.
- The risk
- 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.
- The fix
- 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.
- The problem
- 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.
- The risk
- 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.
- The fix
- 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.
- The problem
- Certain cardone master cylinders with part numbers 10-2925, 10-2987, 10-2987mza, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, and 11-3156, and with date codes lower than dca7078 sold as replacement equipment for use on the vehicles listed above. The seal on master cylinder can fail and leak brake fluid.
- The risk
- Loss of brake fluid can result in poor braking performance, possibly resulting in a vehicle crash.
- The fix
- Cardone will notify owners and offer to repurchase any defective master cylinders. The recall began during april 2007. Owners can contact cardone at 1-800-777-4780.
- The problem
- 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.
- The risk
- This driving condition could eventually lead to separation between the front control arm and the spindle, which could result in a crash.
- The fix
- 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.
What owners say
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198 complaints about the 2004 Volvo S60
Newest first, as filed with NHTSA by owners. Page 1 of 8.
2004 Volvo s60 purchased the car used in sept 04. On 7/8/24 stranded at 7-11 car wouldn't start. Acting as if there was power loss, ac went off, brake failure light on panel, power windows and locks did not work, temp 105 outside , then driver panel went black., I was scared. Engine wouldn't start. Finally, after waiting 10 minutes...It started running but was sluggish. Radio was on, power door, locks, and windows, did not work. Cut the car off and back on, all power returned, now check engine and air bag trouble on panel. Called volvo dealer next day near my home, they can not see my car til next week tuesday. Can not access engine box, must go to dealer.
Starting Sunday November 27 my car started dripping gasoline on the floor, on the driver side near the rear wheel. Immediately I took it to Volvo dealer Wynne in Hampton, VA. The service specialist told me there was not any existing recall for that issue and let me go. That night I put under the leak a flat pan. That night I collected one gallon in about 8 hours. I called Volvo cars USA [[redacted]] explained me the car have been fixed for the campaign #09V483000 in September 14, 2010. I own the car since 2015. I...
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asked her if the recall should be possible to do it again at no cost for me, because it falls under Safety due to the fact the car may get in fire due to the leak of gas. She asked me to go back again to Wynne Volvo dealer and tell to the service specialist that I talked to them and if they wouldn't repair my car I could open a case with Volvo Cars USA. The service specialist told me I could leave the car for inspection, but I would be responsible for at least $180 to get and estimate, but never said that they would fix it under the safety recall number 09V483000 for vehicles sold or registered in the states with hot climate like Virginia. The recall started in January 15, 2010. It covers the fuel pump that can develop cracks in the fuel pump flange. The technician said the repair they did under the recall was replacing an O-Ring gasket only not the fuel pump. The person I talked to in Service is [[redacted]] with Title Service Advisor. Phone number [[redacted]]. I called again today Wednesday November 30, 2022 to Volvo Cars USA they said they can not promise to wave the repair because they need first that I pay $180 for a car diagnostic of the issue. They would probably accept to pay part of the total charge but they would be doing it at good will. I don't have $180 to pay upfront for a safety recall that it didn't last but only 12 years. The Safety recall is valid as long as the car is in service, it doesn't matter if I am or not the first owner. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
The contact owns a 2004 Volvo S60. The contact stated that while operating the vehicle, the instrument panel would not illuminate or operate. During the failure, the fuel gauge, speedometer, odometer, and other information was unavailable to the driver. The cause of the failure was not determined. The local dealer and manufacturer were notified of the failure, but no assistance was offered. The failure mileage was 157,000.
Recall airbags- fuel gauge goes up and down never registers correctly
Driving home from church,, smoke started coming from the drivers seat,from the heated seat. Burned a hole thru the leather . Was able to turn off the switch and put some snow into the golf size hole and pulled the fuse to the elect heat switch. No further damage was noticed .City street. The hole is about 11/2 in below left side beading and closer to front of seat. Leather seat in very good codition and non smoker. Garage keep.
Yes my passenger side seat belt just randomly locked up. My car has never been in any crashes I didn't stop short for it to lock up. I went to put it on and it would only pull half way out and then when it went back it it stuck. It won't come out at all at all now. I can't pass inspection without it working.
My son was in a side impact collision on the passenger side of his 2004 volvo s60. He was in a rural area and either didn't see the oncoming car or missed his stop sign and the oncoming driver was unable to stop. The other driver is uninjured but my son in severely injured with a grade 3 dai head injury. He was wearing his seat belt. The side airbags deployed but not the one in the steering wheel. In an email volvo told me this is how the airbags are designed and that the driver airbags will not deploy on side...
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impact. If that is correct information, this needs to change. The only significant injury my son has is where his head hit the steering wheel, if that airbag had deployed his injuries would have potentially been much less. The airbags are already there, I don't understand why they can't just deploy on any significant impact. I will include pictures.
Tl* the contact owns a 2004 volvo s60. The contact stated while attempting to make a left turn, another vehicle intersected her line causing impact to the front driver's side. The air bags did not deploy. The contact stated that the abs warning light was illuminated prior to the accident. The contact stated no one sustained injuries or sought medical attention. A police report was filed. The vehicle was not drivable. The vehicle was towed to an impound lot. The vehicle failure had not been diagnosed or repaired by a dealer or independent mechanic. The manufacturer had not been informed of the failure. The failure mileage was approximately 162,000. *Ln*jb
Tl* the contact owns a 2004 volvo s60. The contact stated that while stationary, the engine caught fire. The contact stated that smoke entered into the cabin of the vehicle. The contact exited the vehicle and opened the hood, and the engine was surrounded by flames. A police or fire department report was not filed. An independent mechanic extinguished the fire. There were no injuries sustained. A dealer was not made aware of the fire. The manufacturer was not made aware of the fire. The failure mileage was approximately 30,000.
Heated seat shorted when turned on on drivers side and burned me while driving.
Car is volvo s60 2004 trim 2.4 4 Door sedan fwd has 90317 miles on it. From last few weeks when I am driving vehicle it starts losing power and a warning come try slow down or shift up and my check engine light started blinking. This happened 4 times in last 1 week as the result I need to pull my car to safe place and restart that and then it runs better. This has really put me in danger to myself and other people on road. I am scare of driving the car in multiple lane roads in other lanes. I am now driving...
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it on right lane only so that keep myself and other people safe for quick pull over if needed. Check engine gives me code p0171 and p0300. I went on line and followed advice and changed spark plugs, ignition coils and also oxygen sensor but no difference. Still car did same thing when I was driving with my family. I went on line and saw that many people have that issue with volvo s60 of this year and model and struggling. I think this is some volvo s 60 2004 model recall issue as it is creating accidental hazard to the owner of the car and the other traffic. Dr takyar
In stop and go traffic, my foot was on the brake to slow down. I took my foot off the brake and stepped on the accelerator as traffic moved again, there was no response to my foot on the gas pedal. The fuel tank, which I had just filled 10 miles before, showed as empty on the fuel gage. I was very, very slowly rolling forward with residual momentum and my steering wasn't working. There was just enough play in the wheel and forward momentum to aim and arrive at the shoulder of the highway. This was on rte 156 in...
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monterey county, california, where very dangerous accidents happen all the time. Car had to be towed and the dealership has been unable to replicate failure. It was outrageously dangerous and I was alone with my 11-year-old child. So frightening!!!
ENGINE STALLS....MULTIPLE TIMES
Tl* the contact owns a 2004 volvo s60. While driving approximately 65 mph, the vehicle stalled and was pulled over to the side of the road. The vehicle was restarted and there were no warning indicators illuminated. The failure recurred. The dealer was not contacted. The manufacturer was made aware of the failure and referred the contact to nhtsa. The vehicle was not repaired. The failure mileage was approximately 136,000.
I just recently went to a dealer for a gas fuel leak. They noticed a crack in the holder. The mechanic also asked me to check for a recall before fixing due to this being a common problem with some volvos. I am also noticing there is a powersteering leakage somewhere because im constantly putting in powersteering. Please take my complaint in consideration due to it being life threating and I have children who I have to carry around in that vehicle. If its a defective equitment on volvo im asking for immediate replacement. For safety
Tl* the contact owns a 2004 volvo s60. The contact stated that while driving at approximately 40 mph, the check engine warning indicator illuminated. The engine started to hesitate and stalled. The contact coasted to the side of the road and waited for approximately three minutes and restarted the vehicle. The contact drove the vehicle to m.P.L. Automotive laconia new hampshire (independent mechanic). The vehicle was diagnosed with a fuel rail pressure sensor needing replacement and also advised the contact of...
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nhtsa campaign number: 07v226000 (engine and engine coolant). The contact called lovering volvo meredith new hampshire was advised that the vin was part of the recall. The vehicle was not repaired as of yet. The approximate failure mileage was 158,000.
Gasoline fill overflows frequently when putting in fuel, regardless of amount of fuel already in the tank.
Tl* the contact owns a 2004 volvo s60. While driving at various speeds, the vehicle stalled and the check engine light illuminated. The contact coasted the vehicle to the side of the road, restarted the vehicle, and resumed driving. The failure recurred numerous times. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 155,000.
CAR STALLED WHILST BREAKING
Fuel pump leaked. Smell gas. Scared it may catch fire. Expensive repair. Volvo is refusing to honor recall because (1) vehicle purchased in nj (though has spent life in va) and (2) work done at non-volvo mechanic. Due to the severity of the issue, I took it to the nearest mechanic rather than risk driving it to dealer and having it catch fire.
Tl* the contact owns a 2004 volvo s60. The contact stated that while driving at various speeds, the vehicle stalled. The contact was able to restart the vehicle. The check engine warning light illuminated. The failure recurred on numerous occasions. The vehicle was taken to an independent mechanic who diagnosed that the fuel rail pressure sensor needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 140,000.
Tl* the contact owns a 2004 volvo s60. While driving 65 mph, the vehicle stalled. The contact was able to restart the vehicle. The contact stated that the failure recurred several times. The vehicle was taken to be diagnosed at the dealer. The contact was informed that the fuel pressure sensor needed to be replaced. The vehicle was not repaired. The vehicle was not included in nhtsa campaign number: 07v226000 (engine and engine cooling). The manufacturer was not notified of the failure. The approximate failure mileage was 150,000.
Tl* the contact owns a 2004 volvo s60. The contact stated that when turning the key into the ignition switch, the vehicle failed to start. The vehicle was towed to an independent mechanic who diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The vehicle was not included in nhtsa campaign number: 09v483000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 170,000.
Tl* the contact owns a 2004 volvo s60. The contact stated that the vehicle stalled on multiple occasions while driving. The check engine warning indicator illuminated. The vehicle was taken to an independent mechanic who stated that the vin was not included in nhtsa campaign number: 07v226000 (engine and engine cooling). The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 111,000.
March 2014: I was travelling on a divided highway at 55 mph and the car stalled. Mechanic stated it was the fuel pump. Mar 2015 : this same event occurred again. *Tr
Volvo S60: every year compared
| Year | Complaints | Recalls | Grade |
|---|---|---|---|
| 2008 | 10 | 2 | B |
| 2007 | 21 | 2 | C |
| 2006 | 31 | 4 | C |
| 2005 | 44 | 4 | D |
| 2004 | 198 | 6 | F |
| 2003 | 123 | 7 | F |
| 2002 | 189 | 9 | F |
| 2001 | 238 | 9 | F |
| 2000 | 1 | 0 | A |
2004 Volvo S60 vs rivals
| Vehicle | Complaints | Recalls | Grade | |
|---|---|---|---|---|
| 2004 Volvo S60 | 198 | 6 | F | |
| 2004 BMW 3 Series | 558 | 0 | F | Compare |
| 2004 Mercedes-Benz E-Class | 483 | 0 | D | Compare |
| 2004 BMW 5 Series | 320 | 8 | F | Compare |
| 2004 Audi A4 | 189 | 3 | D | Compare |
| 2004 Mercedes-Benz C-Class | 77 | 0 | A | Compare |
| 2004 Audi A6 | 35 | 4 | C | Compare |
| 2004 BMW 330I | 0 | 5 | C | Compare |
| 2004 Lexus IS | 0 | 1 | B | 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 S60
Does the 2004 Volvo S60 have any recalls?
Yes - NHTSA lists 6 recalls for the 2004 Volvo S60: inflator module (September 2021); navigational system(global positioning system) (November 2010); fuel pump (December 2009); engine and engine cooling (June 2007) 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 S60?
By the complaints owners filed with NHTSA, the most common problem areas are the engine & cooling (85), fuel system (55), electrical system (21).
How many complaints has the 2004 Volvo S60 had?
198 complaints have been filed with NHTSA, the first on October 2, 2003 and the latest on July 8, 2024. Of these, 12 describe a crash and 12 a fire, and together they report 8 injuries and 0 deaths.
Is the 2004 Volvo S60 a reliable vehicle?
Its Safety Index is 5 out of 100 (grade F: far more problems than a typical Volvo S60 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 S60 years have the most complaints?
2001 (238), 2004 (198), 2002 (189). See every Volvo S60 year compared.
What should I do if my 2004 Volvo S60 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