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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
28,000 miles · Dec 7, 2006
Power Train

THE GEAR SHIFT HEAD DISINTEGRATED IN MY HAND AS I SHIFTED FROM PARK INTO DRIVE CAUSING THE VEHICLE UNABLE TO BE SHIFTED INTO ANY GEAR BUT "DRIVE". COULD NOT TURN OFF THE VEHICLE, BUT WAS ABLE TO DRIVE INTO THE NEAREST VOLVO DEALER. CONSEQUENCES COULD HAVE BEEN DIRE IF I HAD TO STOP FOR A ROAD/POLICE EMERGENCY. *NM

NHTSA ODI #10175490

Mileage unknown · Nov 7, 2006
Structure

I WAS DRIVING MY 2004 VOLVO S60 ON THE NJ TURNPIKE. WINDS REPORTED THAT DAY TO BE UP TO 50 MPH AND I AM DRIVING AT AROUND 50 TO 60 MPH WHEN I HEARD A LOUD SOUND FROM THE REAR OF MY CAR. I STARTED TO SLOW DOWN TO ENTER ONTO THE BREAKDOWN LANE ON THE TURNPIKE DRAGGING THE BUMPER AS I PULLED OVER. WHEN I GOT OUT TO INSPECT I FOU…

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I WAS DRIVING MY 2004 VOLVO S60 ON THE NJ TURNPIKE. WINDS REPORTED THAT DAY TO BE UP TO 50 MPH AND I AM DRIVING AT AROUND 50 TO 60 MPH WHEN I HEARD A LOUD SOUND FROM THE REAR OF MY CAR. I STARTED TO SLOW DOWN TO ENTER ONTO THE BREAKDOWN LANE ON THE TURNPIKE DRAGGING THE BUMPER AS I PULLED OVER. WHEN I GOT OUT TO INSPECT I FOUND THAT MY BUMPER COVER HAVE BLEW OFF OF THE CAR AND WAS HANGING ON DUE TO A WIRE THAT WAS CONNECTED TO IT ON THE RIGHT SIDE. I CALLED MY VOLVO DEALER AND WAS OFFERED AN APPT TO BRING IT IN. THE SERVICE MANAGER ALONG WITH HIS REGIONAL REP IS DISPUTING THAT THIS COULD HAVE HAPPENED. THEY ARE SAYING THAT THEY HAVE NEVER HEARD OF THIS BEFORE AND THAT IT COULD NOT HAVE HAPPENED BECAUSE IT HAS NEVER HAPPENED AND WILL NOT TAKE RESPONSIBILITY FOR THE REPLACEMENT UNLESS IT IS PAID FOR BY ME. NEITHER THE DEALER OR THE REP IS CONCERNED ABOUT THE SAFETY OF THIS INCIDENT AND WHY THIS ACTUALLY HAPPENED. IT IS BY THE GRACE OF GOD THAT THIS BUMPER COVER DID NOT COMPLETELY DISLODGE CAUSING FATALITIES TO OCCUR HAD THE WIND BLEW IT IN THE PATH OF OTHER CARS ON THE ROADS. NOT ONLY AM I NOT GETTING GOOD SERVICE VOLVO IS NOT CONCERNED ABOUT SAFETY WHICH IS THE CORE OF THEIR COMMITMENT TO THE CONSUMERS. MY CHARACTER AND MY INTEGRITY AND CREDIBILITY IS BEING CHALLENGED BY THE SERVICE MANAGER AND HIS REGIONAL REP RATHER THE REASON FOR THE BUMPER COMING OFF IN THIS WAY. MY CONFIDENT IN THE SAFETY OF THE CAR AND VOLVO CUSTOMER SERVICE HAS BEEN DESTROYED. VOVLO IS SAYING THAT THIS IS THE FIRST TIME THEY HAVE HEARD OF A BUMPER BLOWING OFF. THERE IS ALWAYS A FIRST AND BEING THE FIRST DOES NOT INDICATED THAT IT'S IMPOSSIBLE TO HAVE HAPPENED. *JB

NHTSA ODI #10172870

Mileage unknown · Sep 27, 2006
Fuel System, GasolineCrashInjury

ON SEPTEMBER 18 I WAS TRAVELING DOWN INTERSTATE 10 WHEN MY 2004 VOLVO S60 COMPLETELY STOPPED RUNNING WHILE GOING 70 MPH. I WAS UNABLE TO GET THE CAR OUT OF THE TRAFFIC (NO POWER TO DRIVE TO THE SHOULDER). MY CAR WAS COMPLETELY USELESS. I CALLED 911 AND ROADSIDE ASSISTANCE TO GET HELP BEFORE I WAS HIT (I WAS UNABLE TO EXIT THE…

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ON SEPTEMBER 18 I WAS TRAVELING DOWN INTERSTATE 10 WHEN MY 2004 VOLVO S60 COMPLETELY STOPPED RUNNING WHILE GOING 70 MPH. I WAS UNABLE TO GET THE CAR OUT OF THE TRAFFIC (NO POWER TO DRIVE TO THE SHOULDER). MY CAR WAS COMPLETELY USELESS. I CALLED 911 AND ROADSIDE ASSISTANCE TO GET HELP BEFORE I WAS HIT (I WAS UNABLE TO EXIT THE VEHICLE DUE TO MOVING TRAFFIC ON EITHER SIDE OF ME). AFTER 50 MINUTES I WAS HIT IN THE REAR. THE VEHICLE WAS TOWED TO BERGERON VOLVO. I WAS INFORMED THAT THE FUEL PUMP HAD FAILED. THERE WAS NO WARNING AND THE VEHICLE HAD JUST BEEN IN FOR SERVICE 1 MONTH BEFORE. IT ONLY HAS 24,000 MILES. *JB

NHTSA ODI #10169423

17,500 miles · Jun 26, 2006
Tires

TIRES SIDEWALLS. *NM

NHTSA ODI #10160822

Mileage unknown · May 1, 2006
Electrical System

CAR STOPS WHILE DRIVING. GAUGES ON DASHBOARD DON'T WORK. *JB

NHTSA ODI #10156519

14,300 miles · Apr 20, 2006
Power Train

2004 S60AWD ANGLE GEAR LEAK REQUIRED REPLACEMENT OF GEAR AT 14,300 MILES. THE ANGLE GEAR SENDS POWER TO THE REAR WHEELS, AND IF IT FAILS, IT TAKES THE TRANSMISSION WITH IT. WHILE MINE WAS CAUGHT EARLY AND REPLACED UNDER WARRANTY, A TRACK RECORD OF THE ANGLE GEAR LEAKING AND FAILING IS BEING SEEN. VOLVO NEEDS TO EXTEND WARRAN…

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2004 S60AWD ANGLE GEAR LEAK REQUIRED REPLACEMENT OF GEAR AT 14,300 MILES. THE ANGLE GEAR SENDS POWER TO THE REAR WHEELS, AND IF IT FAILS, IT TAKES THE TRANSMISSION WITH IT. WHILE MINE WAS CAUGHT EARLY AND REPLACED UNDER WARRANTY, A TRACK RECORD OF THE ANGLE GEAR LEAKING AND FAILING IS BEING SEEN. VOLVO NEEDS TO EXTEND WARRANTY ON THIS ITEM. *NM

NHTSA ODI #10155772

28,000 miles · Feb 14, 2006
Suspension

LOUD NOISE FROM REAR WHEELS. FIRST THOUGHT TO BE WORN TIRES. TURNED OUT TO BE THE BEARINGS FAILED. CAUSED DAMAGE TO SPEED SENSOR, ROTOR, REAR AXLE DRIVE SHAFT. CAR SHOOK VIOLENTLY AS SPEEDS WHERE REDUCED. DEALER WILL NOT FIX PROBLEM. ALL PARTS TO BE REPLACED AT OWNERS EXPENSE. *NM

NHTSA ODI #10150235

30 miles · Jan 31, 2006
SteeringSuspension

DT*: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS AND TURNING LEFT OR RIGHT THE TIRES TOUCHES THE FRAME OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION ON FOUR OCCASIONS. THE FIRST TIME THE DEALER PLACED STEERING BLOCKS ON THE VEHICLE. THE SECOND, THIRD AND FOURTH TIMES THE DEALER ADJUSTED THE CONTROL…

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DT*: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS AND TURNING LEFT OR RIGHT THE TIRES TOUCHES THE FRAME OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION ON FOUR OCCASIONS. THE FIRST TIME THE DEALER PLACED STEERING BLOCKS ON THE VEHICLE. THE SECOND, THIRD AND FOURTH TIMES THE DEALER ADJUSTED THE CONTROL ARMS. HOWEVER NONE OF THESE EFFORTS REMEDIED THE PROBLEM. THE PROBLEM CONTINUES AND THE VEHICLE HAS NOT BEEN RETURNED TO THE DEALER FOR FURTHER DIAGNOSTIC TESTING. UPDATED 2/24/2006 - POWER STEERING RESERVOIR LEAKED FLUID FROM THE BOTTOM HOSE NEAR THE CLAMP. THE CONSUMER HEARD A METAL ON METAL SOUND WHILE TURNING THE WHEEL. THE DEALER MODIFIED THE STEERING STOPS. AL FOUR TAILLIGHT AND BOTH LOW BEAM BULB WENT OUT. *NM

NHTSA ODI #10149150

9,000 miles · Jan 24, 2006
Power Train

VOLVO S60 2004, 9000 MILES, AUTOMATIC TRANSMISSION. WHILE LEAVING A TRAFFIC LIGHT (ACCELERATING) AND AT A SPEED OF ABOUT 20 MPH THE ENGINE SUDDENLY STOPPED. NO POWER FOR STEERING AND BRAKES. WHAT COULD HAPPEN IF THE DEFECT OCCURRED ON THE HIGHWAY? THE CAR WAS SERVICED AT VOLVO GARAGE ACCORDING TO MAINTENANCE PROGRAM (6000 MILE…

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VOLVO S60 2004, 9000 MILES, AUTOMATIC TRANSMISSION. WHILE LEAVING A TRAFFIC LIGHT (ACCELERATING) AND AT A SPEED OF ABOUT 20 MPH THE ENGINE SUDDENLY STOPPED. NO POWER FOR STEERING AND BRAKES. WHAT COULD HAPPEN IF THE DEFECT OCCURRED ON THE HIGHWAY? THE CAR WAS SERVICED AT VOLVO GARAGE ACCORDING TO MAINTENANCE PROGRAM (6000 MILES). NOW THEY SAID THAT THE DEFECT WAS DUE TO THE AIR ADMISSION SYSTEM, WHICH WAS FOUND TO BE DIRTY. *AK

NHTSA ODI #10148506

Mileage unknown · Aug 2, 2005
Engine And Engine Cooling

DT: CONSUMER OWNED A 2004 VOLVO S60. ON GOING SINCE APRIL OF 2005 ENGINE REBUILT DUE TO STALLING. VEHICLE STALLED IN TRAFFIC AND DID NOT ACCELERATE PROPERLY. ALSO, VEHICLE SLOWED DOWN AT ONCE FOR NO REASON. WHILE DRIVING AFTER THE ENGINE WAS REBUILT AND WAS MERGING ONTO I87 NORTH AND VEHICLE STALLED. CONSUMER PULLED OFF T…

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DT: CONSUMER OWNED A 2004 VOLVO S60. ON GOING SINCE APRIL OF 2005 ENGINE REBUILT DUE TO STALLING. VEHICLE STALLED IN TRAFFIC AND DID NOT ACCELERATE PROPERLY. ALSO, VEHICLE SLOWED DOWN AT ONCE FOR NO REASON. WHILE DRIVING AFTER THE ENGINE WAS REBUILT AND WAS MERGING ONTO I87 NORTH AND VEHICLE STALLED. CONSUMER PULLED OFF THE RAMP ONTO THE SHOULDER. THEN PAUSED FOR ABOUT FIVE MINUTES TO REGAIN COMPOSURE AND THEN RESTARTED ENGINE. VEHICLE RESTARTED WITH NO PROBLEM. CONSUMER SAID THAT STALL ONLY HAPPENED TWICE. DEALER REPLACED MASS AIRFLOW SENSOR, BUT VEHICLE STILL DID NOT OPERATE CORRECTLY. CONSUMER THOUGHT THAT VEHICLE DID NOT OPERATE PROPERLY BETWEEN 2000 AND 3000 RPMS. THE MANUFACTURER SHOULD DO SOMETHING ABOUT THIS PROBLEM WHICH WAS VERY DANGEROUS. CONSUMER WORRIED ABOUT HER LIFE WHILE DRIVING VEHICLE.*AK

NHTSA ODI #10131117

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.