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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

Vehicle Speed Control complaints

11 reports
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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…

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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

145,000 miles · Feb 5, 2014
EngineVehicle Speed Control

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THERE WAS A SUDDEN LOSS OF ENGINE POWER WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THE THROTTLE BODY AND BODY GASKET NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE V…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THERE WAS A SUDDEN LOSS OF ENGINE POWER WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THE THROTTLE BODY AND BODY GASKET NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 145,000.

NHTSA ODI #10563015

115,000 miles · Aug 22, 2013
EngineFuel/propulsion SystemVehicle Speed Control

CHECK ENGINE LIGHT CAME ON AND CAR LOST POWER WHILE DRIVING AT HIGHWAY SPEEDS. IT WOULD NOT ACCELERATE AND DISPLAYED THE MESSAGE "REDUCED ENGINE PERFORMANCE". DEALER INDICATED IT WAS A CRACKED INTERCOOLER HOSE AND THAT CAUSED THE ISSUE. IT WAS REPLACE AND AFTER ABOUT TWO MONTHS THE SAME SYMPTOMS HAPPENED. IT WAS THEN DIAGNOSED A…

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CHECK ENGINE LIGHT CAME ON AND CAR LOST POWER WHILE DRIVING AT HIGHWAY SPEEDS. IT WOULD NOT ACCELERATE AND DISPLAYED THE MESSAGE "REDUCED ENGINE PERFORMANCE". DEALER INDICATED IT WAS A CRACKED INTERCOOLER HOSE AND THAT CAUSED THE ISSUE. IT WAS REPLACE AND AFTER ABOUT TWO MONTHS THE SAME SYMPTOMS HAPPENED. IT WAS THEN DIAGNOSED AS A BAD ELECTRONIC THROTTLE BODY. THAT WAS REPLACED AND THE SAME SYMPTOMS HAPPENED WITHIN TWO MONTHS AGAIN. THE CAR NOW DOES NOT ACCELERATE MORE THAN 10 MPH. THE NEXT DIAGNOSIS WAS TO REPLACE THE COMPLETE ENGINE WIRING HARNESS. THE CAR IS UNSAFE TO DRIVE BECAUSE IT STALL OR DECELERATE FROM HIGHWAY SPEEDS WITH NO NOTICE. IT IS VERY SIMILAR TO A RECALL FOR MODEL YEARS UP TO 2002. *TR

NHTSA ODI #10536822

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…

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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

72,500 miles · Mar 13, 2012
Service Brakes, HydraulicVehicle Speed ControlCrash

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT WAS DRIVING 25 MPH WITH CRUISE CONTROL ACTIVATED WHEN THE BRAKES WERE DEPRESSED BUT THE VEHICLE FAILED TO STOP. THE CONTACT CRASHED INTO FIVE VEHICLES. THE CONTACT'S VEHICLE WAS DESTROYED. THE POLICE WERE CONTACTED AND A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO A PRIV…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT WAS DRIVING 25 MPH WITH CRUISE CONTROL ACTIVATED WHEN THE BRAKES WERE DEPRESSED BUT THE VEHICLE FAILED TO STOP. THE CONTACT CRASHED INTO FIVE VEHICLES. THE CONTACT'S VEHICLE WAS DESTROYED. THE POLICE WERE CONTACTED AND A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC AND THE MANUFACTURER WAS CONTACTED. UPDATED 04/16/12 *BF THE CONSUMER STATED THE CRUISE CONTROL WAS NOT FUNCTIONING PROPERLY. THE THROTTLE REMAINED OPEN. UPDATED 04/25/12

NHTSA ODI #10451468

92,058 miles · Apr 29, 2011
Engine And Engine CoolingVehicle Speed ControlCrash

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT WAS DRIVING APPROXIMATELY 30 MPH WHEN THE VEHICLE ABNORMALLY ACCELERATED UNTIL CRASHING. THERE WERE NO INJURIES. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER BUT THE FAILURE WAS NOT DIAGNOSED. THE VEHICLE WAS REPAIRED FOR THE BODY DAMAGES. THE FAILURE AND CURRENT MILEAGE WAS 92…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT WAS DRIVING APPROXIMATELY 30 MPH WHEN THE VEHICLE ABNORMALLY ACCELERATED UNTIL CRASHING. THERE WERE NO INJURIES. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER BUT THE FAILURE WAS NOT DIAGNOSED. THE VEHICLE WAS REPAIRED FOR THE BODY DAMAGES. THE FAILURE AND CURRENT MILEAGE WAS 92,058. UPDATED 05/26/11 *BF THE CONSUMER STATED AS SHE MADE A TURN, THE VEHICLE TOOK OFF AT A VERY HIGH SPEED. THE VEHICLE WENT FORM SIDE TO SIDE AS SHE TRIED VERY HARD TO BRAKE AND STEER AWAY FROM THE INCLINE ON THE RIGHT. THIS ACTION CONTINUED FOR ABOUT 0.3 MILES, BEFORE THE VEHICLE AIR LIFTED AND THE RIGHT PASSENGER SIDE BETWEEN THE REAR DOOR AND REAR QUARTER PANEL HIT THE GUARDRAIL. THE VEHICLE THEN BOUNCED OFF THE GUARDRAIL, CROSSED THE STREET, JUMPED THE GUTTER AND LANDED ON ITS WHEELS IN A NEARBY FIELD, WHERE IT CAME TO A STOP. WHEN SHE TRIED TO START THE VEHICLE, SHE KEPT IN THE LOWEST GEAR, WITH HER FOOT ON THE BRAKE AND A MESSAGE LIGHT ILLUMINATED STATING DO NOT DRIVE, COOLANT IS LOW. UPDATED 08/24/11

NHTSA ODI #10398267

50,000 miles · Apr 8, 2011
Vehicle Speed Control

TL*THE CONTACT OWNS A 2004 VOLVO S60 . THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY APPROXIMATELY 65 MPH, THE VEHICLE STALLED. HE MENTIONED THAT THE FAILURE OCCURRED SEVERAL TIMES PRIOR. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THE THROTTLE BODY NEEDED TO BE REPLACED. THE FUEL PRESSURE SENSOR ALSO HAD TO BE REPLACED …

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TL*THE CONTACT OWNS A 2004 VOLVO S60 . THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY APPROXIMATELY 65 MPH, THE VEHICLE STALLED. HE MENTIONED THAT THE FAILURE OCCURRED SEVERAL TIMES PRIOR. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THE THROTTLE BODY NEEDED TO BE REPLACED. THE FUEL PRESSURE SENSOR ALSO HAD TO BE REPLACED UNDER NHTSA CAMPAIGN ID NUMBER: 07V226000 (ENGINE AND ENGINE COOLING ). THE MANUFACTURER WAS CONTACTED AND DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 50,000 AND CURRENT MILEAGE WAS 55,000.

NHTSA ODI #10395299

96,000 miles · Dec 21, 2010
Vehicle Speed Control

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING AT ANY SPEED, THE CONTACT STATED THAT THE VEHICLE WOULD MOVE INTO LIMP MODE, CAUSING THE VEHICLE TO STALL. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. THE CONTACT DID NOT INFORM THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATE…

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TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING AT ANY SPEED, THE CONTACT STATED THAT THE VEHICLE WOULD MOVE INTO LIMP MODE, CAUSING THE VEHICLE TO STALL. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE. THE CONTACT DID NOT INFORM THE MANUFACTURER. THE VEHICLE WAS NOT REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 96,000.

NHTSA ODI #10371941

52,000 miles · Sep 14, 2010
Vehicle Speed Control

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT WOULD ILLUMINATE SPORADICALLY FOLLOWED BY THE VEHICLE STALLING. THE FAILURE WOULD OCCUR MOST OFTEN WHEN DRIVING AT LOW SPEEDS. THE VEHICLE WAS TAKEN TO A LOCAL INDEPENDENT MECHANIC WHO ADVISED THE CONTACT THAT THE FUEL SENSOR WAS DEFECTIVE. T…

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TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT WOULD ILLUMINATE SPORADICALLY FOLLOWED BY THE VEHICLE STALLING. THE FAILURE WOULD OCCUR MOST OFTEN WHEN DRIVING AT LOW SPEEDS. THE VEHICLE WAS TAKEN TO A LOCAL INDEPENDENT MECHANIC WHO ADVISED THE CONTACT THAT THE FUEL SENSOR WAS DEFECTIVE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED BUT WOULD PROVIDE NO ASSISTANCE. THE CURRENT AND FAILURE MILEAGE WAS 52,000. UPDATED 12/03/10. *LJ

NHTSA ODI #10355590

58,650 miles · Jun 19, 2007
Vehicle Speed Control

ON 1/6/07 I WAS TRAVELING VIA INTERSTATE WHEN THE 2004 VOLVO S60T EXPERIENCED WHAT WAS DISPLAYED ON THE SCREEN AS REDUCED ENGINE PERFORMANCE, AND QUICKLY SLOWED TO ABOUT 40 MPH. I WAS VERY NEARLY REAR-ENDED AS I WAS IN THE FAST LANE IN THE PROCESS OF PASSING A SLOWER VEHICLE. I PROCEEDED TO THE NEAREST EXIT AND COASTED INTO A G…

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ON 1/6/07 I WAS TRAVELING VIA INTERSTATE WHEN THE 2004 VOLVO S60T EXPERIENCED WHAT WAS DISPLAYED ON THE SCREEN AS REDUCED ENGINE PERFORMANCE, AND QUICKLY SLOWED TO ABOUT 40 MPH. I WAS VERY NEARLY REAR-ENDED AS I WAS IN THE FAST LANE IN THE PROCESS OF PASSING A SLOWER VEHICLE. I PROCEEDED TO THE NEAREST EXIT AND COASTED INTO A GAS STATION. I TURNED OFF THE CAR AND TRIED TO RESTARTED IT. HOWEVER, IT MADE A LOUD NOISE, SHOOK, AND THEN FAILED TO CRANK. IT WAS TOWED TO THE NEAREST VOLVO DEALERSHIP, WHERE THEY INFORMED ME IT WAS A FAULTY THROTTLE BODY (ETM). THE CAR ONLY HAD 58,000 MILES , 8,000 OUT OF WARRANTY. THE REPAIRS INCLUDED REMOVING AND CLEANING THE ETM, REPLACING THE THROTTLE BODY, AND ETM SOFTWARE RELOADED FOR A TOTAL OF $14,000. 3 MONTHS LATER, WHILE I WAS IN THE HOSPITAL GIVING BIRTH, MY HUSBAND EXPERIENCED THE SAME MALFUNCTION ON THE WAY TO THE HOSPITAL, LOST POWER, AND HAD TO GET ALTERNATE TRANSPORTATION. WE TRADED THE CAR IMMEDIATELY WITHOUT REPAIR. *AK

NHTSA ODI #10193701

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.