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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.

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

What owners actually said

198 reports
78,000 miles · Feb 28, 2008
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 C…

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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 #10219593

24,500 miles · Feb 27, 2008
Engine And Engine CoolingService Brakes, HydraulicCrashInjury

I WAS LEAVING UCLA PARKING GARAGE (I'M AN RN THERE) WHEN I PUT MY VOLVO 2004 S60 INTO GEAR AND IT TOOK OFF BACKWARDS LIKE A ROCKET, CAR WAS THROWN INTO A CONCRETE POST FAR AWAY FROM WHERE I BEGAN. I IMMEDIATELY PUT CAR IN PARK SINCE I THOUGHT I'D GET OUT AND SEE WHAT ON EARTH HAPPENED, BUT IT THEN LUNGED FORWARD BY ITSELF AND TO…

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I WAS LEAVING UCLA PARKING GARAGE (I'M AN RN THERE) WHEN I PUT MY VOLVO 2004 S60 INTO GEAR AND IT TOOK OFF BACKWARDS LIKE A ROCKET, CAR WAS THROWN INTO A CONCRETE POST FAR AWAY FROM WHERE I BEGAN. I IMMEDIATELY PUT CAR IN PARK SINCE I THOUGHT I'D GET OUT AND SEE WHAT ON EARTH HAPPENED, BUT IT THEN LUNGED FORWARD BY ITSELF AND TOOK OFF WITHOUT STOPPING!!! THANK GOD IT WAS 6PM AND NOT AN HOUR EARLIER WHEN MANY STAFF WOULD HAVE BEEN IN GARAGE, I'D HAVE RUN THEM OVER! I ALSO TURNED OFF IGNITION WITH KEY, NOTHING HELPED!! IT KEPT GOING ALONG WITH A MIND OF ITS OWN AT APPROX 15 MPH MAKING A GROWLING WHIRRING SOUND. I WAS ABLE TO STEER CAR AND AVOID OTHER VEHICLES BUT EVENTUALLY HAD TO MAKE SERIOUS DECISION TO PURPOSELY CRASH INTO ANOTHER CONCRETE MASSIVE POST WHICH I DID AND THE "POSSESSED BEAST". FINALLY CAME TO A HALT WITH FLUID POURING OUT ALL OVER,. MY BRAKES DID NOT WORK DURING THIS EVENT, NOT AT ALL, THAT'S WHY I COULDN'T STOP THE CAR (ALONG WITH FOOT ON BRAKE, TRIED PUTTING CAR IN PARK GEAR AND TURNED OFF IGNITION KEY LAST AUGUST WHEN I HAD ONLY 22, 000 MILES ON CAR IT TOOK IT TO VOLVO DEALER TWICE, SINCE CAR WAS OFTEN STALLING AND STOPPING ON THE STREET WHILE I WAS DRIVING. I WAS TOLD THEY COULDN'T FIND IT STALLING WHEN THEY TEST DROVE IT BUT THEY MENTIONED THEY CLEANED THE THROTTLE AND SAID THAT COULD HELP (WHICH IT DID UNTIL 2, 500 MILES LATER WHEN THIS HAPPENED. I HAVE DEALER PAPERWORK INDICATING CAR STALLING AND THAT THEY CLEANED THROTTLE BOX ALSO, THEY SAID I SHOULD BE TAKING CAR ON THE FREEWAY MORE AT HIGH ENOUGH SPEED TO "BLOW OFF THE CARBON" I SPENT FRIDAY NIGHT IN ER WITH NECK/SHOULDER INJURIES, BUT THIS COULD HAVE BEEN A DISASTER. FORGOT TO MENTION THAT WHEN I TOOK CAR IN FOR SERVICE JULY 2007 DEALER REPLACED FUEL PRESSURE SENSOR AS PER RECALL. DON'T KNOW IF THIS IS SIGNIFICANT. ALSO WROTE ON FORM "DURING INSPECTION FOUND UPPER ENGINE MOUNT COLLAPSED, CAUSE........ ENGINE REPAIR". UPDATED 03-25-08 *BF THE DEALER STATED REAR BRAKE PADS HAD TO BE REPLACED. UPDATED 03/25/08 *TR

NHTSA ODI #10219547

1 miles · Feb 27, 2008
Tires

FRONT TIRES ARE RUBBING THE BODY ON THE INSIDE OF THE TIRE. VEHICLE HAS ORIGINAL WHEELS AND TIRES. CHRONIC PROBLEM WITH VOLVO. *TR

NHTSA ODI #10219289

Mileage unknown · Feb 17, 2008
Fuel System, Other

I HAVE HAD THE SAME PROBLEM OF THE CAR STALLING AROUND TURNS AND ON ABRUPT STOPS. IT SEEMED TO FIRST BE RESOLVED BY THE RECALL OF THE PRESSURE SENSOR. RECENTLY THOUGH THE CAR HAS BEEN STALLING SOMETIMES 5 TIMES PER DAY WHEN DOING THE SAME. THE DEALER CLAIMS IT IS A PVC PROBLEM THAT NEEDS TO BE CLEANED AND WANTS TO CHARGE $100…

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I HAVE HAD THE SAME PROBLEM OF THE CAR STALLING AROUND TURNS AND ON ABRUPT STOPS. IT SEEMED TO FIRST BE RESOLVED BY THE RECALL OF THE PRESSURE SENSOR. RECENTLY THOUGH THE CAR HAS BEEN STALLING SOMETIMES 5 TIMES PER DAY WHEN DOING THE SAME. THE DEALER CLAIMS IT IS A PVC PROBLEM THAT NEEDS TO BE CLEANED AND WANTS TO CHARGE $1000 DOLLARS TO DO IT. *TR

NHTSA ODI #10218252

Mileage unknown · Feb 6, 2008
Engine And Engine Cooling

I OWN A 2004 VOLVO S60 2.5T AND RECENTLY HAD PROBLEMS WITH THE ENGINE STALLING IN THE MIDDLE OF A BUSY ROAD. THIS CONCERNS ME BECAUSE OF THE HIGH RISK OF BEING INVOLVED IN A MAJOR ACCIDENT. I'M WORRIED THIS MAY HAPPEN AGAIN. I'VE CONTACTED MY DEALER (PHILLIPS VOLVO 4980 VIRGINIA BEACH BOULEVARD, VIRGINIA BEACH, VA 23462) AND …

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I OWN A 2004 VOLVO S60 2.5T AND RECENTLY HAD PROBLEMS WITH THE ENGINE STALLING IN THE MIDDLE OF A BUSY ROAD. THIS CONCERNS ME BECAUSE OF THE HIGH RISK OF BEING INVOLVED IN A MAJOR ACCIDENT. I'M WORRIED THIS MAY HAPPEN AGAIN. I'VE CONTACTED MY DEALER (PHILLIPS VOLVO 4980 VIRGINIA BEACH BOULEVARD, VIRGINIA BEACH, VA 23462) AND THEY INFORMED ME I DO NOT HAVE A RECALL ON MY VEHICLE. I AM STILL TAKING MY CAR TO THE MECHANIC TO SEE WHAT THE PROBLEM MAY BE. I'VE HAD A "CHECK ENGINE" LIGHT ON AND OFF FOR MANY MONTHS NOW, THE DEALERSHIP HAS CHECKED THIS OUT AND SAID I HAVE NO ERRORS AND MY CAR IS FINE. I AM VERY UNCOMFORTABLE WITH THIS DIAGNOSIS. *TR

NHTSA ODI #10217087

28,180 miles · Jan 11, 2008
Fuel System, Gasoline

STRONG FUEL SMELL COMING FROM INSIDE VEHICLE. FUEL PUMP LEAKING. THE DEFECT WAS NOTED ON 2001-2002 MODEL YEARS BUT NEEDS TO BE EXTENDED TO 2004 FOR VEHICLES IN NEVADA. *TR

NHTSA ODI #10214545

30,000 miles · Jan 10, 2008
Power Train

WHEN ACCELERATING FROM A STOP, THE TRANSMISSION SEEMS TO SKIP A GEAR. THIS RESULTS IN UNEVEN ACCELERATION, MAKING MERGING INTO TRAFFIC HAZARDOUS. IT ONLY HAPPENS SPORADICALLY. *TR

NHTSA ODI #10214467

38,500 miles · Nov 10, 2007
Fuel System, Gasoline

STRONG FUEL ODOR EMITTING FROM PASSENGER SIDE OF VEHICLE. OBSERVED GAS STAINS COVERING OUTSIDE OF GAS TANK. RETURNED TO DEALER AND DEALER REPLACED FUEL PUMP. SINCE THEN, NO ODORS. HOWEVER, AUTO CONTINUES TO HESITATE WHEN DRIVING. IN ONE INSTANCE, CAR STALLED IN HEAVY TRAFFIC AND WAS NEARLY REAR ENDED. *TR

NHTSA ODI #10208579

54,000 miles · Oct 30, 2007
Engine And Engine Cooling

CARS SHUT OFF ON TWO SEPARATE OCCASIONS WITH OUT A MOMENTS NOTICE WITHIN A TWO WEEK PERIOD, ONCE AT A STOP SIGN ANOTHER TIME IN STOP AND GO TRAFFIC ON A MAJOR HIGHWAY. I HAVE ONLY OWNED THIS CAR FOR LESS THAN TWO MONTHS. THERE ARE NO SIGNALS OR CODES LISTED ON THE CAR AS TO WHY IT SHUT OFF. CAR DOESN'T HAVE PROBLEM RESTARTING AT…

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CARS SHUT OFF ON TWO SEPARATE OCCASIONS WITH OUT A MOMENTS NOTICE WITHIN A TWO WEEK PERIOD, ONCE AT A STOP SIGN ANOTHER TIME IN STOP AND GO TRAFFIC ON A MAJOR HIGHWAY. I HAVE ONLY OWNED THIS CAR FOR LESS THAN TWO MONTHS. THERE ARE NO SIGNALS OR CODES LISTED ON THE CAR AS TO WHY IT SHUT OFF. CAR DOESN'T HAVE PROBLEM RESTARTING AT ALL. VOLVO DEALER HAS LISTED THIS CAR AS UP TO DATE WITH ALL RECALLS. ISSUE IS YET TO BE RESOLVED, DUE TO MECHANIC'S NOT EXPERIENCING THE SHUT OFF POINT THEY ARE FAILING TO DIAGNOSE THE SITUATION PERIOD. MY SAFETY IS 1ST, HOWEVER MY CAR MAY SHUT OFF AT ANY POINT, SO I DO NOT FEEL SAFE IN THIS CAR AT ALL. *TR

NHTSA ODI #10207410

Mileage unknown · Sep 27, 2007
Engine And Engine CoolingSteering

LTR RE 2004 VOLVO S60 2.5 T STEERING DEFECT; SEEKING STEERING OF MY VEHICLE BE CORRECTED, RE-ENGINEERED TO THAT OF ANY CURRENT VOLVO SEDAN; PLEASE CONTACT HER BY MAIL OR PHONE WITHIN 14 DAYS OF THIS LETTER. *KB THE CONSUMER STATED THE TIRES WERE RUBBING AGAINST THE STEERING WELL WHEN MAKING TURNS. THE DEALER PERFORMED A TEMPO…

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LTR RE 2004 VOLVO S60 2.5 T STEERING DEFECT; SEEKING STEERING OF MY VEHICLE BE CORRECTED, RE-ENGINEERED TO THAT OF ANY CURRENT VOLVO SEDAN; PLEASE CONTACT HER BY MAIL OR PHONE WITHIN 14 DAYS OF THIS LETTER. *KB THE CONSUMER STATED THE TIRES WERE RUBBING AGAINST THE STEERING WELL WHEN MAKING TURNS. THE DEALER PERFORMED A TEMPORARY FIX BY INSTALLING A STEERING RACK LIMITER TO PREVENT THE TIRE RUBBING. THE CONSUMER CALLED THE DEALER BACK ONCE THE PROBLEM RETURNED AND WAS THEN INFORMED THAT THERE WAS A STEERING ENGINEERING DEFECT WITH THE VEHICLE AND THE MANUFACTURER WAS OFFERING A STEERING REPLACEMENT KIT THAT COULD BE INSTALLED AT NO COST. ONCE THE REPLACEMENT KIT WAS INSTALLED, THE CONSUMER SOON DISCOVERED THE STEERING RADIUS WAS INCREDIBLY DIMINISHED AND THAT SHE COULD NO LONGER MAKE U-TURNS AT AN INTERSECTION. THE DEALER TOLD THE CONSUMER THE STEERING KIT WAS THE ONLY SOLUTION THAT VOLVO OFFERED. THE CONSUMER STATED THE COOLANT LIGHT WAS ON. THE DEALER STATED THE RADIATOR WAS LEAKING. *JB

NHTSA ODI #10204924

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.