← New search

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.

About this comparison →

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

Fuel System, Gasoline complaints

30 reports
Clear category filter
155,000 miles · Nov 10, 2014
Fuel System, Gasoline

MY CAR WAS DYING ON THE HIGHWAY OR ON A REGULAR STREET ROAD. ENDED UP BEING THE FUEL PRESSURE SENSOR WHICH IS ON THE RECALL LIST BUT DIDN'T COME UP FOR MY VIN. I WAS DEALING WITH THIS FOR 6 MONTHS OR SO AND IT WAS VERY DANGEROUS. I DON'T UNDERSTAND WHY MY CAR ISN'T ON THE RECALL LIST. ANY HELP IS APPRECIATED. [XXX] I…

Read full complaint

MY CAR WAS DYING ON THE HIGHWAY OR ON A REGULAR STREET ROAD. ENDED UP BEING THE FUEL PRESSURE SENSOR WHICH IS ON THE RECALL LIST BUT DIDN'T COME UP FOR MY VIN. I WAS DEALING WITH THIS FOR 6 MONTHS OR SO AND IT WAS VERY DANGEROUS. I DON'T UNDERSTAND WHY MY CAR ISN'T ON THE RECALL LIST. ANY HELP IS APPRECIATED. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10654041

130,000 miles · Oct 31, 2014
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE WOULD LOSE POWER AND EXHIBIT A SUDDEN INCREASE IN ENGINE RPMS BEFORE THE VEHICLE ACCELERATED. IN ADDITION, THE CHECK ENGINE WARNING LIGHT ILLUMINATED INTERMITTENTLY. THE DEALER DIAGNOSED THAT THE FUEL PRESSURE SENSOR N…

Read full complaint

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE WOULD LOSE POWER AND EXHIBIT A SUDDEN INCREASE IN ENGINE RPMS BEFORE THE VEHICLE ACCELERATED. IN ADDITION, THE CHECK ENGINE WARNING LIGHT ILLUMINATED INTERMITTENTLY. THE DEALER DIAGNOSED THAT THE FUEL PRESSURE SENSOR NEEDED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS NOTIFIED OF FAILURE. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

NHTSA ODI #10651726

203,000 miles · Jul 16, 2014
Fuel System, GasolineVehicle Speed Control

LOSS ACCELERATION IN THE VEHICLE ON THE HIGHWAY AT 60 MPH. THE CAR WOULD NOT SPEED UP AND CONTINUE TO SLOW DOWN BUT NEVER CAME TO A FULL STOP. I WAS NOT ABLE TO GO PASS 40 MPH IN THE CAR AND ACCELERATION WAS SLOW. FIRST TIME IT HAPPEN, THE DEALER SAID THROTTLE BODY AND OIL COLLECTION SYSTEM NEEDED TO BE REPLACED. I REPLACED B…

Read full complaint

LOSS ACCELERATION IN THE VEHICLE ON THE HIGHWAY AT 60 MPH. THE CAR WOULD NOT SPEED UP AND CONTINUE TO SLOW DOWN BUT NEVER CAME TO A FULL STOP. I WAS NOT ABLE TO GO PASS 40 MPH IN THE CAR AND ACCELERATION WAS SLOW. FIRST TIME IT HAPPEN, THE DEALER SAID THROTTLE BODY AND OIL COLLECTION SYSTEM NEEDED TO BE REPLACED. I REPLACED BOTH. IT HAPPENS AGAIN, TOOK IT TO A DIFFERENT PERSON, THE MECHANIC SAID FUEL CONTROL NEEDED TO BE REPLACED. I REPLACED THAT. IT HAPPEN THE THIRD TIME AND TOOK IT TO DEALER AND HE INFORMED ME THE SPARK PLUGS. I REPLACED THAT. NOW, THE PROBLEM IS STILL HAPPENING. *TR

NHTSA ODI #10610925

112,329 miles · Mar 23, 2014
Fuel System, Gasoline

I HAD MY CAR IN FOR SERVICE AT MY LOCAL VOLVO REPAIR SHOP AND ONE OF THE ITEMS I HAD THEM INVESTIGATE WAS A FUEL SMELL. THEY TOLD ME THEY FOUND A CRACK AT FUEL PUMP SENDER RH SIDE. THEY MENTIONED THAT THEY THOUGHT THERE WAS A RECALL FOR THIS SINCE THEY HAVE SEEN IT SEVERAL TIMES BEFORE AND THAT I SHOULD CONTACT MY VOLVO DEALER…

Read full complaint

I HAD MY CAR IN FOR SERVICE AT MY LOCAL VOLVO REPAIR SHOP AND ONE OF THE ITEMS I HAD THEM INVESTIGATE WAS A FUEL SMELL. THEY TOLD ME THEY FOUND A CRACK AT FUEL PUMP SENDER RH SIDE. THEY MENTIONED THAT THEY THOUGHT THERE WAS A RECALL FOR THIS SINCE THEY HAVE SEEN IT SEVERAL TIMES BEFORE AND THAT I SHOULD CONTACT MY VOLVO DEALER. I JUST LOOKED ONLINE AND FOUND WHAT THEY WERE TALKING ABOUT BUT IT DOES NOT LIST THE STATE WHERE I PURCHASED THE VEHICLE AND RESIDE? I AM THE ORIGINAL OWNER. THE REPAIR SHOP DID CONTACT A LOCAL DEALER FOR ME AND THE DEALER TOLD THEM THAT THERE WAS NOT A RECALL? I GUESS I WILL CONTACT SOME OTHER LOCAL DEALERS THIS WEEK AND SEE WHAT THEY SAY? SEEMS LIKE COLORADO SHOULD HAVE BEEN ADDED TO THIS RECALL EVERY STATE NEAR US IS PART OF IT. IF I CANT GET THIS REPAIRED UNDER THE RECALL WHAT SHOULD I DO TO MAKE IT HAPPEN? *TR

NHTSA ODI #10574239

135,500 miles · Jul 24, 2013
EngineFuel System, Gasoline

DRIVING HOME AFTER PURCHASING THE CAR (YEAH), I WAS TURNING INTO A PARKING LOT, SO MY SPEED WAS DESCENDING AND THE CAR STALLED. I WROTE IT OFF AS MY FAULT BECAUSE IT DID NOT HAPPEN AGAIN UNTIL 3 MONTHS LATER. WITHIN THE PAST 3 WEEKS THE CAR HAS STALLED WHILE IN MOTION APPROX. 6 TIMES. VOLVO STATED THE RECALLED PART FOR THIS ISSU…

Read full complaint

DRIVING HOME AFTER PURCHASING THE CAR (YEAH), I WAS TURNING INTO A PARKING LOT, SO MY SPEED WAS DESCENDING AND THE CAR STALLED. I WROTE IT OFF AS MY FAULT BECAUSE IT DID NOT HAPPEN AGAIN UNTIL 3 MONTHS LATER. WITHIN THE PAST 3 WEEKS THE CAR HAS STALLED WHILE IN MOTION APPROX. 6 TIMES. VOLVO STATED THE RECALLED PART FOR THIS ISSUE WAS REPLACED IN 2009. I NOTIFIED THE DEALER AND HAVE A APPOINTMENT FOR REPAIR, AT MY EXPENSE BECAUSE IT WAS ALREADY REPLACED. MEANWHILE I WILL NOT DRIVE THE CAR DUE TO THE LACK OF SAFETY. WISH I WOULD HAVE RESEARCHED THE CAR MODEL BEFORE PURCHASE. *TR

NHTSA ODI #10531592

103,000 miles · Jun 17, 2013
Fuel System, GasolineVehicle Speed Control

WHILE DRIVING 70 MPH, CAR LOST ACCELERATION AND STALLED WITHOUT WARNING. IF I WOULD HAVE BEEN REAR ENDED GOING AT THIS SPEED I COULD HAVE LOST MY LIFE. CHECK ENGINE LIGHT CAME ON AND ALL CODES ARE ASSOCIATED WITH THE 181 RECALL. CALLED VOLVO AND VOLVO STATED THAT THIS VIN NUMBER WAS NOT PART OF THE RECALL YET I AM EXPERIENCIN…

Read full complaint

WHILE DRIVING 70 MPH, CAR LOST ACCELERATION AND STALLED WITHOUT WARNING. IF I WOULD HAVE BEEN REAR ENDED GOING AT THIS SPEED I COULD HAVE LOST MY LIFE. CHECK ENGINE LIGHT CAME ON AND ALL CODES ARE ASSOCIATED WITH THE 181 RECALL. CALLED VOLVO AND VOLVO STATED THAT THIS VIN NUMBER WAS NOT PART OF THE RECALL YET I AM EXPERIENCING THE SAME EXACT PROBLEM AND HAVE THE SAME EXACT ENGINE CODES WHEN RUNNING A DIAGNOSTICS TEST ASSOCIATED WITH THIS RECALL. *TR

NHTSA ODI #10520078

67,000 miles · Oct 26, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE VEHICLE WOULD FAIL TO ACCELERATE WHEN DRIVING AT VARIOUS SPEEDS. THE CONTACT ALSO STATED THAT THE VEHICLE WOULD INTERMITTENTLY STALL DURING THE FAILURE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND AN INDEPENDENT REPAIR SHOP TO HAVE THE FAILURE DIAGNOSED. TH…

Read full complaint

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE VEHICLE WOULD FAIL TO ACCELERATE WHEN DRIVING AT VARIOUS SPEEDS. THE CONTACT ALSO STATED THAT THE VEHICLE WOULD INTERMITTENTLY STALL DURING THE FAILURE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND AN INDEPENDENT REPAIR SHOP TO HAVE THE FAILURE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE FAILURE WAS DUE TO THE FUEL PRESSURE SYSTEM. THE CONTACT WAS ALSO INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 09V483000 (FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP). THE FAILURE MILEAGE WAS 67,000.

NHTSA ODI #10432885

52,860 miles · Oct 4, 2011
Fuel System, Gasoline

I OWN A 2004 VOLVO S60. I RECENTLY FOUND OUT THAT THERE IS A RECALL ON MY VEHICLE AFTER MY MECHANIC TOLD ME MY CHECK ENGINE LIGHT WAS DUE TO THIS RECALL. VOLVO SAYS THERE IS NO SUCH RECALL AT FIRST, BUT UPON CALLING THE CUSTOMER SERVICE NUMBER I FOUND OUT THAT THERE IS. HOWEVER, THEY SAY IT IS VIN SPECIFIC AND THAT MINE IS NOT …

Read full complaint

I OWN A 2004 VOLVO S60. I RECENTLY FOUND OUT THAT THERE IS A RECALL ON MY VEHICLE AFTER MY MECHANIC TOLD ME MY CHECK ENGINE LIGHT WAS DUE TO THIS RECALL. VOLVO SAYS THERE IS NO SUCH RECALL AT FIRST, BUT UPON CALLING THE CUSTOMER SERVICE NUMBER I FOUND OUT THAT THERE IS. HOWEVER, THEY SAY IT IS VIN SPECIFIC AND THAT MINE IS NOT COVERED. MY MECHANIC SAYS THAT THIS NEEDS TO BE TAKEN CARE OF, FOR THIS PROBLEM CAN CAUSE MY ENGINE TO STALL OUT AT ANYTIME AND CAUSE MY STEERING WHEEL TO JERK AROUND ON THE HIGHWAY. TO ME, THIS IS A HUGE PROBLEM, SOUNDS LIKE THAT IT COULD POTENTIALLY KILL ME ON THE ROAD. HOW CAN SOMETHING THAT CAN BE THIS POTENTIALLY DANGEROUS NOT BE VOLVOS RESPONSIBILITY TO FIX? JUST BECAUSE MY VIN NUMBER IS DIFFERENT DOES NOT MEAN THE PROBLEM IS ANY LESS SERIOUS, THOUGH VOLVO SEEMS TO THINK IT IS. *TR

NHTSA ODI #10428692

112,000 miles · Jul 27, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHEN DRIVING AT VARIOUS SPEEDS, SHE NOTICED THAT THERE WAS AN ODOR OF GASOLINE. A FUEL LEAK WAS ALSO DISCOVERED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY ADVISED HER THAT THE SEAM OF THE FUEL TANK WAS ROTTED AND NEEDED TO BE REPLACED. THE ENTIRE FUEL TANK WAS R…

Read full complaint

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHEN DRIVING AT VARIOUS SPEEDS, SHE NOTICED THAT THERE WAS AN ODOR OF GASOLINE. A FUEL LEAK WAS ALSO DISCOVERED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY ADVISED HER THAT THE SEAM OF THE FUEL TANK WAS ROTTED AND NEEDED TO BE REPLACED. THE ENTIRE FUEL TANK WAS REPLCACED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS APPROXIMATELY 112,000.

NHTSA ODI #10415341

72,600 miles · Jul 11, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 75 MPH, THE CONTACT STATED THAT SHE APPLIED PRESSURE TO THE ACCELERATOR PEDAL; HOWEVER, SHE WAS UNABLE TO ACCELERATE WHEN SHE NOTICED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE DEALER HAD NOT BEEN NOTIFIED. THE MANUFACTURER WAS AWARE OF THE FAILURE. THE VEHICLE W…

Read full complaint

TL* THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 75 MPH, THE CONTACT STATED THAT SHE APPLIED PRESSURE TO THE ACCELERATOR PEDAL; HOWEVER, SHE WAS UNABLE TO ACCELERATE WHEN SHE NOTICED THAT THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE DEALER HAD NOT BEEN NOTIFIED. THE MANUFACTURER WAS AWARE OF THE FAILURE. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHO INSPECTED THE VEHICLE AND INFORMED THE CONTACT THAT THE FUEL REGULATOR PRESSURE SENSOR HAD FAILED AND NEEDED TO BE REPLACED. NO REPAIRS WERE PERFORMED. THE CURRENT MILEAGE WAS 73,000. THE APPROXIMATE FAILURE MILEAGE WAS 72,600.

NHTSA ODI #10411848

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.