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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.

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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

Air Bags complaints

9 reports
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Mileage unknown · Jul 8, 2024
Air BagsElectrical SystemEngine

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 MIN…

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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.

NHTSA ODI #11600289

Mileage unknown · Oct 21, 2021
Air BagsFuel/propulsion System

RECALL AIRBAGS- FUEL GAUGE GOES UP AND DOWN NEVER REGISTERS CORRECTLY

NHTSA ODI #11437725

215,000 miles · Oct 13, 2020
Air BagsStructureCrashInjury

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 …

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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 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.

NHTSA ODI #11364098

162,000 miles · Mar 9, 2020
Air BagsService Brakes, AirCrash

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 INJU…

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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

NHTSA ODI #11317095

103,800 miles · Sep 18, 2013
Air BagsService BrakesStructureCrashInjury

I WAS DRIVING 35-40 MPH WHEN A VEHICLE 2 CARS AHEAD OF ME HAD TO MAKE A QUICK STOP. I DID NOT SEE THIS HAPPEN IN TIME, SLAMMED ON MY BRAKES AND CONSEQUENTLY SMASHED INTO THE BACK OF THE CAR IN FRONT OF ME, WHO THEN HIT THE CAR IN FRONT OF HIM. I TOTALED MY CAR. THE PASSENGER AIR BAG DEPLOYED AND FILLED MY CAR WITH SMOKE (OR WHAT…

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I WAS DRIVING 35-40 MPH WHEN A VEHICLE 2 CARS AHEAD OF ME HAD TO MAKE A QUICK STOP. I DID NOT SEE THIS HAPPEN IN TIME, SLAMMED ON MY BRAKES AND CONSEQUENTLY SMASHED INTO THE BACK OF THE CAR IN FRONT OF ME, WHO THEN HIT THE CAR IN FRONT OF HIM. I TOTALED MY CAR. THE PASSENGER AIR BAG DEPLOYED AND FILLED MY CAR WITH SMOKE (OR WHATEVER THAT IS) HOWEVER, THE DRIVER AIR BAG DID NOT DEPLOY. I WAS RUSHED TO A TRAUMA CENTER AND MY INJURIES INCLUDE MY BACK, NECK AND I LOST A TOOTH FROM MY FACE HITTING THE STEERING WHEEL. MY CHEST AND LEGS ARE COVERED IN BRUISES FROM THE SEAT BELT. I AM VERY LUCKY, HOWEVER, I DO NOT LIKE TO THINK OF WHAT COULD HAVE OCCURRED IF I WAS AT A HIGH SPEED AND ON THE FWY. AND THE AIR BAG DID NOT DEPLOY BECAUSE IT WAS DEFECTIVE, AND PERHAPS IT WAS NOT DESIGNED TO GO OFF IN THIS PARTICULAR INCIDENT? I HIT HEAD ON, NO LOGICAL REASON TO THINK THE PASSENGER AIRBAG GOING OFF AS IT DID, BUT NOT MINE OR DRIVER SIDE. *JB

NHTSA ODI #10544288

95,000 miles · Aug 10, 2010
Air BagsPower TrainCrashInjury

WHEN PULLING INTO A PARKING SPACE AT MY DAUGHTER'S SCHOOL, VEHICLE SUDDENLY ACCELERATED OVER THE SIDEWALK AND STRUCK THE BUILDING. TRANSMISSION POPPED IN REVERSE AND VEHICLE ACCELERATED BACKWARDS. EVEN WITH THE BRAKE PEDAL ALL THE WAY TO THE FLOOR, VEHICLE WOULD NOT STOP. I FORCED THE TRANSMISSION INTO PARK AND TURNED OFF THE…

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WHEN PULLING INTO A PARKING SPACE AT MY DAUGHTER'S SCHOOL, VEHICLE SUDDENLY ACCELERATED OVER THE SIDEWALK AND STRUCK THE BUILDING. TRANSMISSION POPPED IN REVERSE AND VEHICLE ACCELERATED BACKWARDS. EVEN WITH THE BRAKE PEDAL ALL THE WAY TO THE FLOOR, VEHICLE WOULD NOT STOP. I FORCED THE TRANSMISSION INTO PARK AND TURNED OFF THE VEHICLE TO GET IT TO STOP AFTER GOING IN REVERSE FOR APPROXIMATELY 50 FEET. THERE WAS SIGNIFICANT DAMAGE TO THE CAR AND BUILDING (PICTURES AVAILABLE). NONE OF THE AIRBAGS DEPLOYED. *TR

NHTSA ODI #10348425

41,000 miles · Aug 29, 2008
Air BagsCrashInjury

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING BETWEEN 25-30 MPH, THE CONTACT STRUCK A DEER AND THE VEHICLE FLIPPED OVER. NONE OF THE AIR BAGS DEPLOYED. A POLICE REPORT WAS FILED. THE VEHICLE WAS DESTROYED. THE CONTACT SUSTAINED BACK AND NECK INJURIES. THE CONTACT HAS PICTURES. THE CURRENT AND FAILURE MILEAGES WERE 4…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING BETWEEN 25-30 MPH, THE CONTACT STRUCK A DEER AND THE VEHICLE FLIPPED OVER. NONE OF THE AIR BAGS DEPLOYED. A POLICE REPORT WAS FILED. THE VEHICLE WAS DESTROYED. THE CONTACT SUSTAINED BACK AND NECK INJURIES. THE CONTACT HAS PICTURES. THE CURRENT AND FAILURE MILEAGES WERE 41,000.

NHTSA ODI #10240176

58,000 miles · Jul 28, 2008
Air BagsEngine And Engine CoolingService Brakes, Electric

2004 VOLVO S60 2.5 TURBO: NO WARNING TO THE EVENTS. ON NUMEROUS OCCASIONS, THE CAR FEELS AS IF IT HAS HIT A LARGE OBJECT, TEMPORARILY LURCHES AND APPEARS TO MOMENTARILY STALL CREATING A TEMPORARY LOSS OF VEHICLE CONTROL. THIS IS FOLLOWED BY AN IMMEDIATE LOSS OF ALL INSTRUMENT GAUGES, AIR CONDITIONER, WINDOW CONTROLS AND DOOR…

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2004 VOLVO S60 2.5 TURBO: NO WARNING TO THE EVENTS. ON NUMEROUS OCCASIONS, THE CAR FEELS AS IF IT HAS HIT A LARGE OBJECT, TEMPORARILY LURCHES AND APPEARS TO MOMENTARILY STALL CREATING A TEMPORARY LOSS OF VEHICLE CONTROL. THIS IS FOLLOWED BY AN IMMEDIATE LOSS OF ALL INSTRUMENT GAUGES, AIR CONDITIONER, WINDOW CONTROLS AND DOOR LOCKS. THE FAN DID CONTINUE TO WORK. THE ABS WARNING LIGHT ALSO INDICATED AS WELL AS A WARNING THAT NO BRAKES FUNCTION EXISTED. THE SRS SERVICE AIR BAG URGENT INDICATION IS ILLUMINATED. ON TURNING THE CAR OFF AND RESTARTING, THE FUNCTIONS OF THE CAR RETURN WITH EXCEPTION THAT THE SRS SERVICE AIR BAG URGENT INDICATION REMAINS. THIS PROBLEM CAN TAKE MONTHS TO REPEAT OR ONLY A MATTER OF MINUTES. IT SEEMS TO BE MORE PREVALENT IN HOT WEATHER. THE VEHICLE WAS TAKEN TO THE SERVICE SHOP AT THE VOLVO DEALER AND THEY COULD ONLY CLEAR ALARMS AS THEY SAID THE EVENT CREATED TOO MANY ALARMS/FAULT CODES TO TROUBLESHOOT. THEY DOWNLOADED NEW SOFTWARE REVISIONS TO EACH CONTROL MODULE IN THE CAR. AFTER A PERIOD OF APPROXIMATELY A MONTH, THE EVENTS BEGAN OCCURRING AGAIN. THE VEHICLE HAS BEEN TAKEN TO NON OEM MECHANICS AS WELL AND THEY ARE NOT ABLE TO TROUBLESHOOT THE FAULT. THE VEHICLE IS SCHEDULED TO BE TAKEN TO THE DEALERS SERVICE SHOP AGAIN. SEARCHING THE INTERNET CHAT ROOMS AND BLOGS, AS WELL AS THIS SITE, THERE APPEARS TO BE NUMEROUS OTHER VEHICLES WITH THIS SAME SAFETY FAULT THAT STALLS VEHICLES IN TRAFFIC AND CREATES VERY SUDDEN AND SEVERE LURCHES IN POWER ULTIMATELY LEADING TO A MOMENTARY STALL OUT WITH LOSS OF ALL INSTRUMENT INDICATIONS TO INCLUDE SPEED, RPM, TURN INDICATOR, ETC. *TR

NHTSA ODI #10236160

49,000 miles · Mar 20, 2007
Air BagsCrashInjury

ON MARCH 12 MY VOLVO S-60R WAS T-BONED"BY A LARGE SUV ORD EXPLORER THAT IMPACTED A POINT NEAR MY FRONT DRIVER'S-SIDE WHEEL. THE SUV IMPACT CAUSED MAJOR DAMAGE TO THE FRONT END BY TOTALLY REMOVING THE VOLVO'S BUMPER AND MANGLING THE FRONT DRIVER QUARTER PANEL DOWN TO THE CHASSIS. ALTHOUGH MY CAR WAS SENT SPINNING BY THE FORCE OF …

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ON MARCH 12 MY VOLVO S-60R WAS T-BONED"BY A LARGE SUV ORD EXPLORER THAT IMPACTED A POINT NEAR MY FRONT DRIVER'S-SIDE WHEEL. THE SUV IMPACT CAUSED MAJOR DAMAGE TO THE FRONT END BY TOTALLY REMOVING THE VOLVO'S BUMPER AND MANGLING THE FRONT DRIVER QUARTER PANEL DOWN TO THE CHASSIS. ALTHOUGH MY CAR WAS SENT SPINNING BY THE FORCE OF THE COLLISION. NONE OF THE AIRBAGS DEPLOYED AT THIS INITIAL IMPACT. AS MY VOLVO PROCEEDED TO SPIN CLOCKWISE ACROSS THE PAVEMENT IT IMPACTED THE OVER PASS GUARD-RAIL SUCH THAT THE DRIVER'S SIDE SLAMMED INTO THE GUARD-RAIL, PINNING ME IN THE VEHICLE. ONLY THE PASSENGER FRONT AIRBAG DEPLOYED ON HITTING THE GUARD RAIL AND RELEASING MUCH SMOKE INTO THE CABIN. EVEN THOUGH THIS WAS AN ABRUPT, VIOLENT IMPACT , BOTH WHEN THE SUV HIT ME, AND WHEN MY CAR SLAMMED INTO THE GUARD RAIL THE ONLY COMPONENT OF THE AIRBAG/COLLISION CURTAIN SYSTEM TO FUNCTION WAS THE DASHBOARD INSTALLED PASSENGER AIR BAG. IT IS IMPORTANT TO NOTE THAT THERE WAS NO OTHER PERSON TRAVELING IN THE VOLVO BUT ME. THE FRONT PASSENGER SEAT AND THE REAR SEATS- WERE EMPTY. WITHIN ABOUT 12 HOURS OF THE ACCIDENT I WROTE VOLVO AMERICA TO EXPRESS MY EXTREME DISSATISFACTION WITH THE FAILURE OF THE CAR'S SAFETY SYSTEM.*AK

NHTSA ODI #10185603

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.