KnownCarProblems2004 Volvo S40 Problems and Recalls
Owners filed 48 complaints with NHTSA about the 2004 Volvo S40, most often about the brakes (25% of complaints, typically around 42,000 miles). It is 5th of 12 S40 model years by number of complaints and has 6 recalls.
Most common 2004 Volvo S40 problems
Brakes
12 complaints · 25%Half of these problems showed up before 42,000 miles. Parts named most often: pedals and linkages, power assist, antilock, foundation components.
Brake pedal is too close to accelerator pedal. Whenever I operate the gas pedal, the side of my shoe also activates the brake. The problem is aggravated by the center tunnel carpet intruding on the minimal accelerator pedal space.
I am writing to officially inform you of a problem that continues to need to be replaced on my 2004 S40. I have owed the car since 2006 and am about to bring it in for the forth (4) time to have the hydraulic brake valve pump and hoses replaced. Only this time it is not under warranty because I have 65k miles on the…
Air bags
11 complaints · 23%Half of these problems showed up before 84,500 miles. Parts named most often: frontal.
The event leading up to the failure is simply a defective part after some usage due to a poor welding job at manufacture. Volvo has only recalled one vehicle to my knowledge but they needed to recall all vehicles during that year. The failure is the car has a hard time stopping when the brakes are applied the care…
The contact owns a 2004 Volvo S40. While the contact started the ignition, the air bag warning indicator began to illuminate continuously until the engine was turned off. The vehicle was taken to an authorized dealer, where the front driver's side air bag was replaced. One year later, after the repair was performed…
Electrical
11 complaints · 23%Half of these problems showed up before 51,000 miles. Parts named most often: instrument cluster/panel, 12v/24v/48v battery.
I was driving home at night when all of the gauges in my car went out completely. I had no speedometer, no gas reading, no engine heat meter, the message center was out, no turn signals. This is a 2 year old vehicle that was purchased brand new from Volvo in 2004. I had to drive home 60 miles on an extreme;y dark road…
Tl contact owns a 2004 Volvo S40. While driving 30 MPH, the vehicle rapidly accelerated automatically. The vehicle would not slow down when the brake pedal was depressed. The contact had a difficult time pulling the vehicle over to the side of the road. The vehicle behind her notified her that the vehicle was on fire.…
Fuel system
8 complaints · 17%Parts named most often: delivery, storage.
On certain Volvo vehicles, insufficient sealing of the fuel pump electronic module may lead to water ingress corrosion, possibly causing the unit to fail. This may result in increased, decreased, or loss of fuel pressure. Engine stalling would result in lost propulsion which, in conjunction with traffic and road…
Tl contact owns a 2004 Volvo S40. While driving approximately 30 MPH, the contact stated that the check engine warning light illuminated when the vehicle suddenly stalled without warning. The failure was similar to NHTSA campaign id number: 08v033000 (fuel system, gasoline:delivery:fuel pump). The dealer refused to…
Engine
7 complaints · 15%Parts named most often: engine.
The contact owns a 2004 Volvo S40. While driving 50 MPH the check engine light illuminated on the instrument control panel, and then the vehicle stalled. After a period of waiting she was able to restart the vehicle. The Volvo manufacturer was notified, but no assistance was provided. The failure mileage was 48,000.
The contact owns a 2004 Volvo S40. The contact stated the brake warning light would illuminate while driving at any speed, causing the vehicle to shut down. The vehicle was taken to the dealer three times for the failure and the dealer reprogrammed the computer software each time. On a separate occasion, the failure…
Steering
4 complaints · 8%Parts named most often: rack and pinion.
Dashboard went crazy, fading in and out. All panels were unreadable, speedometer, radio, temperature gauge. Car accelerated on its own, without my foot on the pedal. Cd was shot into the backseat landing in my child safety seat. All of this occurred while driving on the highway. In all 3 instances the message…
Tl contact owns a 2004 Volvo S40. While driving 60 MPH, the contact experienced extreme difficulty steering the vehicle. The first time he took the vehicle to the dealer, they stated that hard steering was a common characteristic of that model vehicle. He took the vehicle back to the dealer and was informed that the…
Speed control
4 complaints · 8%Parts named most often: accelerator pedal.
Dashboard went crazy, fading in and out. All panels were unreadable, speedometer, radio, temperature gauge. Car accelerated on its own, without my foot on the pedal. Cd was shot into the backseat landing in my child safety seat. All of this occurred while driving on the highway. In all 3 instances the message…
Tl contact owns a 2004 Volvo S40. While attempting to park the vehicle with the brake pedal depressed, the vehicle accelerated on its own and crashed into a telephone pole. The contact was uninjured. The vehicle was taken to the dealer and they repaired the damages at the cost of $8,000. The cause of the failure could…
Complaints are owner reports to NHTSA, not verified defects. One complaint can name several components, so shares add up to more than 100%.
2004 Volvo S40 recalls
Equipment: navigational system(global positioning system)
Risk: An overheated battery could lead to a fire.
Fix: 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.
Full defect summary
Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (GPS) units because the batteries on those units may overheat.
Fuel system: fuel pump
Risk: If this occurs, the check engine light may illuminate. In some cases, the vehicle may fail to start or may stall, increasing the risk of a crash.
Fix: Dealers will replace the pem and install it in a new location to prevent corrosion. The recall began on february 20, 2008. Owners may contact volvo at 1-800-458-1552.
Full defect summary
On certain vehicles sold in or currently registered in the states of connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia, reoccurring, long-term exposure to certain environmental conditions such as salty-wet conditions, it is possible for the pump electronic module (pem) to become corroded internally. This can cause a faulty signal to the fuel pump, resulting in low or no fuel pressure to the engine.
Fuel system: fuel system, gasoline
Risk: This may potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
Fix: Dealers will change the fuel line material to teflon free of charge. The recall began on june 5, 2006. Owners may contact volvo cars at 1-800-458-1552.
Full defect summary
On certain passenger vehicles equipped with t5 turbo engines, the polyamide tube in the fuel line is sensitive to the extreme temperatures that may occur in the area where the turbo/exhaust manifold is located.
Brakes: hoses, lines/piping, and fittings
Risk: If this occurs, more brake pedal force may be required to stop the vehicle and/or may experience a rough engine idle, which could result in a crash.
Fix: Dealers will inspect, and if necessary, replace the vacuum hose. The recall began on november 29, 2004. Owners should contact volvo cars at 1-800-458-1552.
Full defect summary
On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
Fuel system: fuel system, gasoline
Risk: Fuel leakage in the presence of an ignition source could result in a fire.
Fix: Dealers will install a v-clamp to the fuel rail. Owner notification began on january 28, 2004. Owners should contact volvo at 1-800-458-1552.
Full defect summary
On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
Equipment: labels
Risk: This does not meet the requirements of the standard.
Fix: Owners will receive a letter/package consisting of the second isofix guide with installation instructions, and in certain cases, the corrected owner's manual may be provided. If the owner wants to take their vehicle to a volvo dealer for installation of the guide, it will be performed at no charge to the owner. Owner notification began on december 19, 2003. Owners should contact volvo at 1-800-458-1552.
Full defect summary
Certain passenger cars fail to comply with the requirements of federal motor vehicle safety standard no. 225, "child restraint anchorage systems." the second isofix guide was not installed in these vehicles and, in certain cases, the owner's manual isofix information is incorrect.
Recall repairs are free at any franchised dealer. Enter your VIN at nhtsa.gov/recalls to see which recalls are still open on your car.
Questions about the 2004 Volvo S40
- What are the most common problems with the 2004 Volvo S40?
- By NHTSA owner complaints: brakes (12 complaints, typically around 42,000 miles); air bags (11 complaints, typically around 84,500 miles); electrical (11 complaints, typically around 51,000 miles).
- How many recalls does the 2004 Volvo S40 have?
- 6 recalls listed by NHTSA, the latest from November 8, 2010 (equipment). Check your VIN at nhtsa.gov/recalls to see which ones are still open on your car.
- Is the 2004 a bad year for the Volvo S40?
- It is 5th of 12 S40 model years by number of complaints, with 48 complaints. Complaint counts are not adjusted for how many cars were sold, so popular years collect more of them, and the newest years have had less time to.