HAVING A COOLANT LEAKAGE, CRASH MODE AND SAFETY ALARM SYSTEM CHECK KEEPS COMING ON...WHEN CRASH MODE COMES ON...CAR JUST SHUTS OFF.
2004 Volvo S40
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2004 Volvo S40 do not stand out strongly from the model-year median of 26.
About this comparison →How this year compares
Owner complaints by model year
Compare all S40 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
35 reports with mileage · 13 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.
- Air Bags. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 11 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Service Brakes, Hydraulic. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
48 reportsTL* 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 …
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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…
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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 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 TRAF…
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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 & 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 …
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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 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…
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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 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 SOLV…
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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 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 MANUFACTURE…
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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.
Official recalls
610V566000 · 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.
08V033000 · Fuel System, Gasoline:delivery:fuel Pump
Jan 28, 2008
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.
Consequence & remedy
Consequence: 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.
Remedy: 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.
06V137000 · Fuel System, Gasoline
Apr 24, 2006
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.
Consequence & remedy
Consequence: THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: 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.
04V493000 · Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/piping, And Fittings
Oct 14, 2004
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
Consequence & remedy
Consequence: 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.
Remedy: 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.
03V424000 · Fuel System, Gasoline
Oct 24, 2003
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
Consequence & remedy
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: 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.
03V284000 · Equipment:other:labels
Aug 1, 2003
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.
Consequence & remedy
Consequence: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.
Remedy: 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.
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
0No exact-year investigations in this snapshot.
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