2004 Volvo S60 Problems, Complaints & Recalls
- Compared with other S60 years
- Far more complaints than other years 2nd of 26 for complaints
- Safety recalls
- 5 recalls: check your VIN
- NHTSA crash rating
- Not rated
Owners have filed 198 complaints with NHTSA about the 2004 Volvo S60. That ranks 2nd out of 26 S60 model years for complaints. The most reported problem area is engine and engine cooling (63 complaints, 32%), typically at around 78,623 miles. Complaints mention 12 crashes, 12 fires, 8 injuries. There are 5 safety recalls covering this model year.
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- 198owner complaints
- 5safety recalls
- 0NHTSA investigations
- 12complaints mentioning a crash
Complaints are unverified owner reports and are not adjusted for sales volume.
Most common 2004 Volvo S60 problems
Complaints grouped by the part of the car owners reported, with the median mileage when the problem happened.
| Problem area | Complaints | Share | Median miles | Owners mention most | Typical repair cost |
|---|---|---|---|---|---|
| Engine and Engine Cooling problems | 63 | 32% | 78,623 | “fuel pressure sensor” (33%) | — |
| Fuel System, Gasoline | 30 | 15% | 77,000 | — | — |
| Engine | 22 | 11% | 106,000 | — | — |
| Electrical System | 21 | 11% | 101,166 | — | — |
| Fuel/propulsion System | 18 | 9% | 121,500 | — | — |
| Power Train | 12 | 6% | 30,000 | — | — |
| Seats | 12 | 6% | 107,000 | — | — |
| Vehicle Speed Control | 11 | 6% | 92,058 | — | — |
| Air Bags | 9 | 5% | 95,000 | — | — |
| Steering | 9 | 5% | 100,000 | — | — |
| Tires | 9 | 5% | 27,250 | — | — |
| Exterior Lighting | 7 | 4% | 82,927 | — | — |
| Fuel System, Other | 7 | 4% | 82,000 | — | — |
| Equipment | 4 | 2% | 90,500 | — | — |
| Structure | 4 | 2% | 103,800 | — | — |
| Service Brakes | 3 | 2% | 100,000 | — | — |
| Service Brakes, Hydraulic | 3 | 2% | 70,000 | — | — |
| Suspension | 3 | 2% | 28,000 | — | — |
| Latches/locks/linkages | 2 | 1% | 119,500 | — | — |
| Parking Brake | 2 | 1% | 88,800 | — | — |
| Seat Belts | 2 | 1% | 102,500 | — | — |
| Visibility | 2 | 1% | 64,000 | — | — |
| Child Seat | 1 | 1% | 40,000 | — | — |
| Electronic Stability Control | 1 | 1% | 200 | — | — |
| Service Brakes, Air | 1 | 1% | 162,000 | — | — |
| Service Brakes, Electric | 1 | 1% | 58,000 | — | — |
One complaint can list several problem areas, so shares can add up to more than 100%.
Complaints by year received
2004 Volvo S60 recalls (5)
Tap a recall to see the problem, the risk and the fix.
Air bags:frontal:driver side:inflator module
Problem: 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.
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.
Equipment:electrical:navigational system(global positioning system)
Problem: Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
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.
Fuel system, gasoline:delivery:fuel pump
Problem: 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.
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.
Engine and engine cooling
Problem: 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.
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.
Steering:linkages
Problem: 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.
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.
To see whether a specific car still has an open recall, enter its VIN on NHTSA's official recall lookup. You can also decode a VIN here.
Recent owner reports
Short excerpts of the latest complaints filed with NHTSA, with personal details removed. Full reports can be searched on NHTSA.gov.
2004 VOLVO S60 PURCHASED THE CAR USED IN SEPT 04. On 7/8/24 STRANDED AT 7-11 CAR WOULDN'T START. ACTING AS IF THERE WAS POWER LOSS, AC WENT OFF, BRAKE FAILURE LIGHT ON PANEL, POWER WINDOWS AND LOCKS DID NOT WORK, TEMP 105 OUTSIDE , THEN DRIVER PANEL WENT BLACK., I WAS SCARED. ENGINE WOULDN'T START…
Starting Sunday November 27 my car started dripping gasoline on the floor, on the driver side near the rear wheel. Immediately I took it to Volvo dealer Wynne in Hampton, VA. The service specialist told me there was not any existing recall for that issue and let me go. That night I put under the…
The contact owns a 2004 Volvo S60. The contact stated that while operating the vehicle, the instrument panel would not illuminate or operate. During the failure, the fuel gauge, speedometer, odometer, and other information was unavailable to the driver. The cause of the failure was not determined…
Recall airbags- fuel gauge goes up and down never registers correctly
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…
Other Volvo S60 years
| Year | Complaints | Recalls |
|---|---|---|
| 2025 S60 | 0 | 2 |
| 2024 S60 | 22 | 3 |
| 2023 S60 | 3 | 6 |
| 2022 S60 | 15 | 4 |
| 2021 S60 | 8 | 3 |
| 2020 S60 | 11 | 4 |
| 2019 S60 | 25 | 4 |
| 2018 S60 | 4 | 1 |
| 2017 S60 | 17 | 5 |
| 2016 S60 | 25 | 4 |
| 2015 S60 | 58 | 2 |
| 2014 S60 | 25 | 3 |
| 2013 S60 | 87 | 4 |
| 2012 S60 | 121 | 8 |
| 2011 S60 | 5 | 6 |
| 2009 S60 | 7 | 3 |
| 2008 S60 | 10 | 2 |
| 2007 S60 | 21 | 2 |
| 2006 S60 | 31 | 3 |
| 2005 S60 | 44 | 3 |
| 2004 | 198 | 5 |
| 2003 S60 | 120 | 6 |
| 2002 S60 | 186 | 8 |
| 2001 S60 | 223 | 8 |
| 2000 S60 | 1 | 0 |
| 1999 S60 | 0 | 0 |
See all Volvo S60 problems by year, every Volvo model, or the Volvo VIN decoder.
Similar Volvo models
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Frequently asked questions
What are the most common problems with the 2004 Volvo S60?
Owners most often report engine and engine cooling, fuel system, gasoline, engine problems. The top one, engine and engine cooling, accounts for 63 complaints.
Was there a recall on the 2004 Volvo S60?
Yes, 5 safety recalls. Enter your VIN at NHTSA.gov to check whether the repairs were done on your car.
Was the 2004 Volvo S60 a good year?
Complaint data can't fully answer that, because counts aren't adjusted for sales. Compared with other S60 model years, the 2004 has far more complaints than most years. Always get a pre-purchase inspection and check the VIN for open recalls.