KnownCarProblems2004 Volvo S60 Problems and Recalls
Owners filed 198 complaints with NHTSA about the 2004 Volvo S60, most often about the engine (43% of complaints, typically around 81,000 miles). It is the 2nd most complained-about S60 model year since 2000 and has 5 recalls.
Most common 2004 Volvo S60 problems
Engine
85 complaints · 43%Half of these problems showed up before 81,000 miles. Parts named most often: engine, cooling system, exhaust system.
2004 Volvo S60 engine stalls without warning, error code of "fuel pressure sensor" indicated by check engine light/onboard diagnostics. Exact same problem is already part of NHTSA recall bulletin reference number(s): 07v226000 however, not all 2004 S60 VIN's are being covered. This is an extremely dangerous situation!…
When I drive my manual transmission s60r Volvo, and I shift I hear a loud thud in the back of the car, I checked everything that could possibly be making the noise and secured it, it bothered me so much I took it to the Volvo dealer and they told me that it was actually because of the suspension software and that…
Fuel system
55 complaints · 28%Half of these problems showed up before 88,500 miles. Parts named most often: delivery, fuel injection system.
Tl contact's spouse owns a 2004 Volvo S60. On approximately twenty occasions, the vehicle would completely shut off and need to be restarted intermittently. The failure occurred while braking or turning the vehicle. The dealer was able to duplicate the failure, but could not get an error code from the diagnostic…
The contact owns a 2004 Volvo S60. The contact stated that while traveling 30 MPH the instrument panel began to illuminate then the vehicle stalled. The vehicle was able to be restarted to proceed to the contact's destination. The vehicle was taken to a dealer where it was found that the fuel injector had failed. The…
Electrical
21 complaints · 11%Half of these problems showed up before 101,000 miles. Parts named most often: ignition, instrument cluster/panel.
1/22/08 inserted key and it would only move into the first position activating the radio, lights, etc. Unable to continue to turn key and turn on automobile. Steering column lock assembly failed, although it is expected to last the life of the car, leaving me stranded and without a car for over a week since part comes…
While driving, the car jerks violently - the same thing happens when the car is idling (no jerk, only an "click" sound). It happens anytime but seems worse in the summer but I think it's hot-heat related. The other issues are related: -the interior lights usually come on -the instrument panel goes completely…
Transmission
12 complaints · 6%Half of these problems showed up before 30,000 miles. Parts named most often: automatic transmission.
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.
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.
Seats
12 complaints · 6%Half of these problems showed up before 107,000 miles. Parts named most often: front assembly.
Tl contact owns a 2004 Volvo S60. The contact stated that while the heated driver side seat was in the on position, a burning odor started to emit inside the vehicle. After inspecting the vehicle, the contacted discovered a flame coming from the side of the driver seat. The contact indicated that the flame self…
Driving home from church,, smoke started coming from the drivers seat,from the heated seat. Burned a hole thru the leather . Was able to turn off the switch and put some snow into the golf size hole and pulled the fuse to the elect heat switch. No further damage was noticed .city street. The hole is about 11/2 in…
Speed control
11 complaints · 6%Half of these problems showed up before 92,000 miles. Parts named most often: cables.
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…
Tl 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…
Wheels and tires
9 complaints · 5%Half of these problems showed up before 27,500 miles. Parts named most often: sidewall.
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…
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…
Steering
9 complaints · 5%Half of these problems showed up before 100,000 miles.
The 2.4l 2004 Volvo S60 experiences erratic behavior and engine failure when operating multiple concurrent electrical systems. When these systems (operated within specified guidelines) are used concurrently they cause the following conditions: engine failure, loss of power steering, loss of brakes. The following is a…
1/22/08 inserted key and it would only move into the first position activating the radio, lights, etc. Unable to continue to turn key and turn on automobile. Steering column lock assembly failed, although it is expected to last the life of the car, leaving me stranded and without a car for over a week since part comes…
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 S60 recalls
Air bags: inflator module
Risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Fix: 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.
Full defect summary
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.
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 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.
Fix: 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.
Full defect summary
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.
Engine: engine and engine cooling
Risk: 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.
Fix: 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.
Full defect summary
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.
Steering: linkages
Risk: This driving condition could eventually lead to separation between the front control arm and the spindle, which could result in a crash.
Fix: 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.
Full defect summary
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.
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 S60
- What are the most common problems with the 2004 Volvo S60?
- By NHTSA owner complaints: engine (85 complaints, typically around 81,000 miles); fuel system (55 complaints, typically around 88,500 miles); electrical (21 complaints, typically around 101,000 miles).
- How many recalls does the 2004 Volvo S60 have?
- 5 recalls listed by NHTSA, the latest from September 30, 2021 (air bags). 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 S60?
- It is the 2nd most complained-about S60 model year since 2000, with 198 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.