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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

What owners actually said

198 reports
57,983 miles · Sep 4, 2007
Engine And Engine Cooling

2004 VOLVO 60 SERIES ENGINE SHUTS OFF WHILE DRIVING.*KB THE CONSUMER STATED SHE RECEIVED A RECALL IN THE MAIL DESCRIBING THE SAME PROBLEM THAT SHE EXPERIENCED. *JB

NHTSA ODI #10202609

60,000 miles · Sep 2, 2007
Engine And Engine Cooling

I HAVE A 2004 VOLVO S60. IN THE PAST ONE YEAR IT KEEPS STALLING BOTH IN MOTION AND WHEN GOING INTO DRIVE FROM PARK. THIS CREATES A DANGEROUS SITUATION WHILE OPERATING THE VEHICLE, ESPECIALLY WHEN IN MOTION AT HIGHWAY SPEEDS. I HAVE TAKEN THE VEHICLE TO VOLVO AUTHORIZED SERVICE TWICE WITH NO RESOLUTION. THE LAST STALL WAS ON AUGU…

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I HAVE A 2004 VOLVO S60. IN THE PAST ONE YEAR IT KEEPS STALLING BOTH IN MOTION AND WHEN GOING INTO DRIVE FROM PARK. THIS CREATES A DANGEROUS SITUATION WHILE OPERATING THE VEHICLE, ESPECIALLY WHEN IN MOTION AT HIGHWAY SPEEDS. I HAVE TAKEN THE VEHICLE TO VOLVO AUTHORIZED SERVICE TWICE WITH NO RESOLUTION. THE LAST STALL WAS ON AUGUST 30, 2007 RESULTING IN THE CAR BEING TOWED TO VOLVO SERVICE. A RECALL WAS ISSUED ON 2004 S40 DUE TO A SIMILAR COMPLAINT, BUT I WAS TOLD THAT THE RECALL DID NOT APPLY SINCE THE VEHICLE WAS AN ALL WHEEL DRIVE. *TR

NHTSA ODI #10201715

7,800 miles · Jul 20, 2007
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING 60 MPH, THE VEHICLE LOST POWER STEERING AND THE BRAKES FAILED. THE CONTACT SHIFTED INTO NEUTRAL AND THEN TURNED OFF AND RESTARTED THE VEHICLE. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE CURRENT MILEAGE IS 32,000 AND FAILURE MILEAGE WAS 7,800.

NHTSA ODI #10197082

29,875 miles · Jul 12, 2007
Tires

I OWN A VOLVO S60 AND HAVE UNDER 30,000 MILES ON THE VEHICLE. YESTERDAY I SUFFEREDTHE SECOND BLOW OUT ON THE CONTINENTAL CONTITOURING CONTACT TIRES, 215/55R16 93H CH95. I AM CONCERNED FOR MY SAFETY AND THE SAFETY OF OTHERS AS THESE TIRES APPEAR TO BE DEFECTIVE WITH TWO BLOW OUTS IN UNDER 30,000 MILES. THE TIRES ARE RATED T…

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I OWN A VOLVO S60 AND HAVE UNDER 30,000 MILES ON THE VEHICLE. YESTERDAY I SUFFEREDTHE SECOND BLOW OUT ON THE CONTINENTAL CONTITOURING CONTACT TIRES, 215/55R16 93H CH95. I AM CONCERNED FOR MY SAFETY AND THE SAFETY OF OTHERS AS THESE TIRES APPEAR TO BE DEFECTIVE WITH TWO BLOW OUTS IN UNDER 30,000 MILES. THE TIRES ARE RATED TO 60,000 MILES. *AK

NHTSA ODI #10196178

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

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

46,000 miles · Mar 8, 2007
Fuel System, Gasoline

I HAVE A VOLVO S60 2004. AROUND JANUARY 2007, IT STARTED STALLING WITHOUT WARNING IN THE MIDDLE OF THE HIGHWAY AT 60 MPH. IT DID THIS ABOUT 3 TIMES IN 2 WEEKS, SO I TOOK IT TO THE VOLVO DEALER. THEY COULDN'T REPRODUCE THE PROBLEM, BUT SUPPOSEDLY UPGRADED THE SOFTWARE AND CLEANED THE THROTTLE INTAKE, AND RETURNED THE CAR TO ME…

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I HAVE A VOLVO S60 2004. AROUND JANUARY 2007, IT STARTED STALLING WITHOUT WARNING IN THE MIDDLE OF THE HIGHWAY AT 60 MPH. IT DID THIS ABOUT 3 TIMES IN 2 WEEKS, SO I TOOK IT TO THE VOLVO DEALER. THEY COULDN'T REPRODUCE THE PROBLEM, BUT SUPPOSEDLY UPGRADED THE SOFTWARE AND CLEANED THE THROTTLE INTAKE, AND RETURNED THE CAR TO ME. THE CAR WAS FINE UNTIL MARCH 6, WHEN THE SAME PROBLEM OCCURRED. THE CAR IS CURRENTLY BACK AT THE SHOP WHERE THEY HAVE TOLD ME THEY HAVE FOUND NOTHING WRONG AND ARE GOING TO RETURN THE CAR TO ME. I WOULD NOT LIKE TO GET KILLED ON THE HIGHWAY, AND AS I HAVE SEEN THAT THIS HAS BEEN REPORTED BEFORE ON OTHER INTERNET SITES, ITS WORTH REPORTING HERE. *JB

NHTSA ODI #10184546

26,800 miles · Feb 28, 2007
Vehicle Speed ControlCrash

TL*- WHILE PARKING THE 2004 VOLVO S60 IN THE DRIVEWAY THE VEHICLE SUDDENLY LURCHED FORWARD, CAUSING THE FRONT WHEELS TO GO OVER A CEMENT BLOCK, HITTING THE HOUSE LIGHTLY. SMOKE STARTED COMING FROM THE ENGINE, AND THE SERVICE ENGINE LIGHT ILLUMINATED ON THE DASHBOARD. THE CONTACT HAD THE VEHICLE TOWED TO A BODY SHOP SINCE TH…

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TL*- WHILE PARKING THE 2004 VOLVO S60 IN THE DRIVEWAY THE VEHICLE SUDDENLY LURCHED FORWARD, CAUSING THE FRONT WHEELS TO GO OVER A CEMENT BLOCK, HITTING THE HOUSE LIGHTLY. SMOKE STARTED COMING FROM THE ENGINE, AND THE SERVICE ENGINE LIGHT ILLUMINATED ON THE DASHBOARD. THE CONTACT HAD THE VEHICLE TOWED TO A BODY SHOP SINCE THERE WAS SOME SLIGHT DAMAGE IN THE FRONT OF THE VEHICLE. CONTACT COULD PROVIDE PICTURES IF NEEDED. THE CURRENT AND FAILURE MILEAGE WERE BOTH 26800.*AK

NHTSA ODI #10183806

27,250 miles · Feb 18, 2007
Tires

2004 VOLVO S60 R WITH 18" TIRES. INSIDE DRIVER TIRE CONTACTS INSIDE DRIVER TIRE WALL. WEAR WILL CAUSE PREMATURE TIRE FAILURE. DEALER HAS ALWAYS MAINTAINED THAT THIS "RUBBING" IS NOT A PROBLEM. I HAVE COMPLAINED MULTIPLE TIMES. I HAVE PHOTOS OF THE TIRE DAMAGE. THE SIDE WALL AND CORNER TREAD IS WORN THROUGH TO THE STEEL BELT AN…

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2004 VOLVO S60 R WITH 18" TIRES. INSIDE DRIVER TIRE CONTACTS INSIDE DRIVER TIRE WALL. WEAR WILL CAUSE PREMATURE TIRE FAILURE. DEALER HAS ALWAYS MAINTAINED THAT THIS "RUBBING" IS NOT A PROBLEM. I HAVE COMPLAINED MULTIPLE TIMES. I HAVE PHOTOS OF THE TIRE DAMAGE. THE SIDE WALL AND CORNER TREAD IS WORN THROUGH TO THE STEEL BELT AND CORD. I HAVE BEEN TOLD THAT THIS IS NOT DUE TO ALIGNMENT, BUT MATCHES UP WITH THE RUBBING OF THE TIRE WELL WALL. *JB

NHTSA ODI #10182906

40,000 miles · Jan 7, 2007
Child SeatSeat Belts

IN REGARD TO A 2004 S60 VOLVO 2.5 AWD-T WE NOTICED A SEAT BELT PROBLEM WITH THE BACK SEAT CENTER SEAT BELT. WE SECURED OUR INFANT CAR SEAT BASE WITH THE CENTER SEAT BELT, AND HAVE BEEN DOING SO SINCE SHE WAS BORN. THE LOCAL POLICE STATION HAD A SERVICE THAT DEMONSTRATED PROPER INSTALLATION AND INSURED WE WERE ABLE TO DO IT OUR…

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IN REGARD TO A 2004 S60 VOLVO 2.5 AWD-T WE NOTICED A SEAT BELT PROBLEM WITH THE BACK SEAT CENTER SEAT BELT. WE SECURED OUR INFANT CAR SEAT BASE WITH THE CENTER SEAT BELT, AND HAVE BEEN DOING SO SINCE SHE WAS BORN. THE LOCAL POLICE STATION HAD A SERVICE THAT DEMONSTRATED PROPER INSTALLATION AND INSURED WE WERE ABLE TO DO IT OURSELVES. THE OFFICER THEN INSTALLED IT FOR US WITH NO PROBLEM. TODAY WE NOTICED THE BASE WAS REALLY LOOSE! I TRIED TO REINSTALL THE SEAT BY ATTACHING IT TO THE SEAT BELT IN THE USUAL FASHION. HOWEVER, I DISCOVERED THAT THE SEAT BELT DID NOT HOLD THE BASE TIGHTLY AS IT DID BEFORE!!! IN SUMMARY- NORMAL USE LED UP TO THE FAILURE OF THE THREE POINT SAFETY BELT IN THE REAR CENTER SEAT POSITION TO PROPERLY HOLD THE BASE OF AN INFANT CAR SEAT SAFELY. WE ARE GOING TO CALL THE DEALER FIRST THING IN THE MORNING AND HAVE IT FIXED. *JB

NHTSA ODI #10178026

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.