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.
Electrical System complaints
11 reportsTHE 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.
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
WHEN DRIVING MY CAR, HE START GOING FASTER WITHOUT PRESSING A GAS PEDAL WHEN I PRESS THE BRAKE THE CAR TURN OFF, I PUT THE GEAR CHANGING ON PARK AND START THE CAR AGAIN, THE RPM START GOING CRAZY, THE CAR HAVE ONLY 30000 MILES. *TW
TL*THE CONTACT OWNS A 2004 VOLVO S40. WHILE DRIVING 30 MPH, THE VEHICLE RAPIDLY ACCELERATED AUTOMATICALLY. THE VEHICLE WOULD NOT SLOW DOWN WHEN THE BRAKE PEDAL WAS DEPRESSED. THE CONTACT HAD A DIFFICULT TIME PULLING THE VEHICLE OVER TO THE SIDE OF THE ROAD. THE VEHICLE BEHIND HER NOTIFIED HER THAT THE VEHICLE WAS ON FIRE. F…
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TL*THE CONTACT OWNS A 2004 VOLVO S40. WHILE DRIVING 30 MPH, THE VEHICLE RAPIDLY ACCELERATED AUTOMATICALLY. THE VEHICLE WOULD NOT SLOW DOWN WHEN THE BRAKE PEDAL WAS DEPRESSED. THE CONTACT HAD A DIFFICULT TIME PULLING THE VEHICLE OVER TO THE SIDE OF THE ROAD. THE VEHICLE BEHIND HER NOTIFIED HER THAT THE VEHICLE WAS ON FIRE. FLAMES APPEARED WHILE ATTEMPTING TO PULL OVER THE VEHICLE. THE POLICE DEPARTMENT WAS NOTIFIED. THE VEHICLE WAS TOWED TO HER RESIDENCE AND THEN TO THE VOLVO DEALER. THE TIRES AND OTHER EQUIPMENT WERE DAMAGED BY THE FLAMES. THE VEHICLE IS CURRENTLY BEING DIAGNOSED BY THE DEALER. THE FAILURE AND CURRENT MILEAGES WERE 65,000.
DASHBOARD WENT CRAZY, FADING IN AND OUT. ALL PANELS WERE UNREADABLE, SPEEDOMETER, RADIO, TEMPERATURE GAUGE. CAR ACCELERATED ON ITS OWN, WITHOUT MY FOOT ON THE PEDAL. CD WAS SHOT INTO THE BACKSEAT LANDING IN MY CHILD SAFETY SEAT. ALL OF THIS OCCURRED WHILE DRIVING ON THE HIGHWAY. IN ALL 3 INSTANCES THE MESSAGE INDICATOR STAT…
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DASHBOARD WENT CRAZY, FADING IN AND OUT. ALL PANELS WERE UNREADABLE, SPEEDOMETER, RADIO, TEMPERATURE GAUGE. CAR ACCELERATED ON ITS OWN, WITHOUT MY FOOT ON THE PEDAL. CD WAS SHOT INTO THE BACKSEAT LANDING IN MY CHILD SAFETY SEAT. ALL OF THIS OCCURRED WHILE DRIVING ON THE HIGHWAY. IN ALL 3 INSTANCES THE MESSAGE INDICATOR STATED TO NOT DRIVE THE CAR. I HAD THE CAR TOWED TO 2 DIFFERENT DEALERS. THE FIRST TIME THEY SAID IT WAS THE SOFTWARE AND REINSTALLED. THE SECOND TIME, THEY REPLACED THE ALTERNATOR AND THE CAR WAS IN THE SHOP FOR OVER A WEEK, THE THIRD TIME, THE REPLACE THE CEM MODULE AND RADIO. THE THE FOURTH TIME THE CAR WOULDN'T READ THE KEY AND HAD TO BE TOWED AND THEY REPLACED THE STEERING MODULE. THIS CAR HAS BEEN IN THE SHOP 3 TIMES IN LESS THAN 6 MONTHS FOR 3 ELECTRICAL RELATED ISSUES THE CAR ONLY HAS 42,000 MILE. *TR
CAR WAS SERVICED ON 25-OCT AT ~49K MILES. NO COMPUTER UPDATES WERE DONE TO THE VEHICLE. 12-DEC, I HAD NEW TIRES PUT ON THE CAR. 13-DEC THE CAR REPORTED "REDUCED ENGINE PERFORMANCE" AND OIL LIGHT CAME ON. PULLED OVER, STOPPED CAR, WAITED A FEW MINUTES AND RESTARTED WITH NO PROBLEM/LIGHTS. DROVE A FEW MILES, SAME EXACT THING …
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CAR WAS SERVICED ON 25-OCT AT ~49K MILES. NO COMPUTER UPDATES WERE DONE TO THE VEHICLE. 12-DEC, I HAD NEW TIRES PUT ON THE CAR. 13-DEC THE CAR REPORTED "REDUCED ENGINE PERFORMANCE" AND OIL LIGHT CAME ON. PULLED OVER, STOPPED CAR, WAITED A FEW MINUTES AND RESTARTED WITH NO PROBLEM/LIGHTS. DROVE A FEW MILES, SAME EXACT THING HAPPENED AGAIN. THEN DROVE FOR ~45 MINUTES WHEN THE CAR REPORTED SOMETHING LIKE A "SYSTEM ENGINE FAILURE" AND THE CHECK ENGINE LIGHT CAME ON. CAR WAS SPUTTERING WITH NO RESPONSE FROM THE GAS PEDAL. WAS TOWED TO MY DEALERSHIP. SM INFORMED ME THAT THE "MAIN" COMPUTER HAD FAILED, "TWO OTHER COMPUTERS" HAD "STOPPED COMMUNICATING" AND THE "THROTTLE MODULE" FAILED. HE TOLD ME THEY COULD FIX THE CAR FOR ~$300 WITH COMPUTER UPGRADES. HE DIDN'T KNOW IF THAT WOULD FIX THE THROTTLE MODULE AS WELL. IT WAS FIXED IN THEIR OPINION AFTER THEY ROAD TESTED IT FOR ~7 MILES. HE SAID AVAILABLE COMPUTER UPGRADES ARE ALWAYS APPLIED AT THEIR DEALERSHIP WHEN THE CAR IS UNDER WARRANTY BUT NEVER WHEN THE CAR IS OUT OF WARRANTY UNLESS THERE'S A PROBLEM. WAS TOLD MY EXTENDED WARRANTY DID NOT COVER THE UPGRADES AND WAS CHARGED ~$300. I ASKED IF THE UPGRADES COULD HAVE BEEN APPLIED 25-OCT SINCE I WAS UNDER WARRANTY. HE FELT THAT THEY COULD HAVE BEEN, ASSUMING THE UPGRADES WERE AVAILABLE THEN BUT COULDN'T TELL ME IF THEY WERE. SPOKE WITH THE SM AT THE DEALERSHIP WHERE I WAS ON 25-OCT AND HE SAID THEY NEVER APPLY COMPUTER UPGRADES UNLESS THERE'S A PROBLEM WITH THE CAR, WARRANTY OR NOT. DROVE THE CAR HOME ON 13-DEC AND NOTICED "ELECTRICAL" ISSUES. DROVE THE CAR ON THE MORNING OF 14-DEC AND A HEADLIGHT WENT OUT AND CAME BACK ON LATER IN THE DAY. CAR FAILED AGAIN THAT DAY IN TRAFFIC. FILED A CASE WITH VOLVO CUSTOMER CARE. *JB DEALERSHIP HAS CLEANED THE THROTTLE MODULE BUT PROBLEM PERSISTS. THEY ORDERED A NEW ETM AT ~$800. I WAS TOLD THAT THEY WILL USE THE $300 AS A 25% PAYMENT ON THE PARTS/LABOR FOR THE ETM REPLACEMENT AND THERE WILL BE NO ADDITIONAL COST TO ME.
I WAS DRIVING HOME AT NIGHT WHEN ALL OF THE GAUGES IN MY CAR WENT OUT COMPLETELY. I HAD NO SPEEDOMETER, NO GAS READING, NO ENGINE HEAT METER, THE MESSAGE CENTER WAS OUT, NO TURN SIGNALS. THIS IS A 2 YEAR OLD VEHICLE THAT WAS PURCHASED BRAND NEW FROM VOLVO IN 2004. I HAD TO DRIVE HOME 60 MILES ON AN EXTREME;Y DARK ROAD WITH NO…
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I WAS DRIVING HOME AT NIGHT WHEN ALL OF THE GAUGES IN MY CAR WENT OUT COMPLETELY. I HAD NO SPEEDOMETER, NO GAS READING, NO ENGINE HEAT METER, THE MESSAGE CENTER WAS OUT, NO TURN SIGNALS. THIS IS A 2 YEAR OLD VEHICLE THAT WAS PURCHASED BRAND NEW FROM VOLVO IN 2004. I HAD TO DRIVE HOME 60 MILES ON AN EXTREME;Y DARK ROAD WITH NO SAFETY GAUGES- I COULDN'T CALL FOR ROADSIDE AS I WAS ALONE AND AM A WOMAN- I WASN'T GOING TO STOP ON THE SIDE OF THE ROAD TO WAIT FOR ROADSIDE. I WAS TOLD BY VOLVO THAT IT WAS THE DDM MODULE AND THE WIRING HARNESS- MY ELECTRICAL /COMPUTER SYSTEM WENT BAD. HOW IS THAT POSSIBLE IN A BRAND NEW CAR? FURTHERMORE, I WAS 1,000 MILES OVER THE MANUFACTURER'S WARRANTY OF 50,000 MILES- THUS VOLVO CHARGED ME $1,645.00. WITHIN IN MINUTES OF DRIVING THE CAR AFTER IT WAS REPAIRED- THE SERVICE ENGINE LIGHT CAME ON. I WAS TOLD THAT MY SOFTWARE HAD TO BE UPGRADED AND MY THROTTLE CLEANED? I BELIEVE THAT THE ELECTRICAL/COMPUTER SYSTEMS IN THESE CARS ARE NO GOOD. *NM
THE VEHICLE HAS THE FOLLOWING INTERMITTENT ELECTRICAL PROBLEMS. DASHBOARD, RADIO, CLIMATE CONTROLS TURN-OFF BY THEMSELVES. WIPERS ACTIVATE BY THEMSELVES. SRS WARNINGS ARE DISPLAYED. FUEL DOOR BUTTON DOES NOT ACTIVATE. IGNITION WILL NOT ACTIVE SO CAR WILL NOT START. *JB
2004 VOLVO S40 EXPERIENCING PROBLEMS WITH THE REAR TAIL LIGHT ASSEMBLY. *MR THE LEFT REAR TAIL LIGHT ASSEMBLY WAS INTERMITTENT. AT NIGHT THERE WOULD BE NO REAR TAIL LIGHTS. THE RIGHT FRONT PARK LIGHT AND THE YELLOW SIDE MARKER LIGHT HAD GONE OUT AS WELL. THE DEALER REPLACED THE CEM. THE VEHICLE'S BATTERY LASTED 8 MONTHS.…
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2004 VOLVO S40 EXPERIENCING PROBLEMS WITH THE REAR TAIL LIGHT ASSEMBLY. *MR THE LEFT REAR TAIL LIGHT ASSEMBLY WAS INTERMITTENT. AT NIGHT THERE WOULD BE NO REAR TAIL LIGHTS. THE RIGHT FRONT PARK LIGHT AND THE YELLOW SIDE MARKER LIGHT HAD GONE OUT AS WELL. THE DEALER REPLACED THE CEM. THE VEHICLE'S BATTERY LASTED 8 MONTHS. *SC
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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