RoadVitals

2004 Volvo S60

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
198
Latest Jul 8, 2024
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
6
Latest Sep 30, 2021
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
24
8 injuries, 0 deaths reported

Overview

Our database contains 198 NHTSA owner-reported complaints for the 2004 Volvo S60, most frequently naming the engine, fuel system and electrical categories. 6 safety recalls have been issued covering this model year; and 182 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

6 campaigns cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Sep 30, 2021
259,383 units potentially affected
The defect: 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.
The risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
The 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.
Volvo Car USA, LLCManufacturer number R10125View on NHTSA.gov

EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

Nov 8, 2010
416 units potentially affected
The defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
The risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
The 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.
VOLVO CARS OF N.A. LLC.Manufacturer number R231View on NHTSA.gov

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Dec 18, 2009
158,733 units potentially affected
The defect: 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.
The 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.
The 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.
VOLVO CARS OF N.A. LLC.Manufacturer number R220View on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

AirbagsElectricalEngine
Filed Jul 8, 2024

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. FINALLY, AFTER WAITING 10 MINUTES...IT STARTED RUNNING BUT WAS SLUGGISH. RADIO WAS ON, POWER DOOR, LOCKS, AND WINDOWS, DID NOT WORK. CUT THE CAR OFF AND BACK ON, ALL POWER RETURNED, NOW CHECK ENGINE AND AIR BAG TROUBLE ON PANEL. CALLED VOLVO DEALER NEXT DAY NEAR MY HOME, THEY CAN NOT SEE MY CAR TIL NEXT WEEK TUESDAY. CAN NOT ACCESS ENGINE BOX, MUST GO TO DEALER.

NHTSA ID
11600289
Incident
Jul 8, 2024
Fuel system
Filed Nov 30, 2022

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 leak a flat pan. That night I collected one gallon in about 8 hours. I called Volvo cars USA [XXX] explained me the car have been fixed for the campaign #09V483000 in September 14, 2010. I own the car since 2015. I asked her if the recall should be possible to do it again at no cost for me, because it falls under Safety due to the fact the car may get in fire due to the leak of gas. She asked me to go back again to Wynne Volvo dealer and tell to the service specialist that I talked to them and if they wouldn't repair my car I could open a case with Volvo Cars USA. The service specialist told me I could leave the car for inspection, but I would be responsible for at least $180 to get and estimate, but never said that they would fix it under the safety recall number 09V483000 for vehicles sold or registered in the states with hot climate like Virginia. The recall started in January 15, 2010. It covers the fuel pump that can develop cracks in the fuel pump flange. The technician said the repair they did under the recall was replacing an O-Ring gasket only not the fuel pump. The person I talked to in Service is [XXX] with Title Service Advisor. Phone number [XXX]. I called again today Wednesday November 30, 2022 to Volvo Cars USA they said they can not promise to wave the repair because they need first that I pay $180 for a car diagnostic of the issue. They would probably accept to pay part of the total charge but they would be doing it at good will. I don't have $180 to pay upfront for a safety recall that it didn't last but only 12 years. The Safety recall is valid as long as the car is in service, it doesn't matter if I am or not the first owner. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA)

NHTSA ID
11495569
Incident
Nov 27, 2022
Electrical
Filed Nov 22, 2021

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. The local dealer and manufacturer were notified of the failure, but no assistance was offered. The failure mileage was 157,000.

NHTSA ID
11441285
Incident
Apr 1, 2021
Mileage
157,000 mi
AirbagsFuel system
Filed Oct 21, 2021

RECALL AIRBAGS- FUEL GAUGE GOES UP AND DOWN NEVER REGISTERS CORRECTLY

NHTSA ID
11437725
Incident
Mar 20, 2020
Interior & seats
Filed Apr 5, 2021
Fire reported

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 BELOW LEFT SIDE BEADING AND CLOSER TO FRONT OF SEAT. LEATHER SEAT IN VERY GOOD CODITION AND NON SMOKER. GARAGE KEEP.

NHTSA ID
11406424
Incident
Mar 7, 2021
Mileage
107,000 mi
Seat belts
Filed Mar 10, 2021

YES MY PASSENGER SIDE SEAT BELT JUST RANDOMLY LOCKED UP. MY CAR HAS NEVER BEEN IN ANY CRASHES I DIDN'T STOP SHORT FOR IT TO LOCK UP. I WENT TO PUT IT ON AND IT WOULD ONLY PULL HALF WAY OUT AND THEN WHEN IT WENT BACK IT IT STUCK. IT WON'T COME OUT AT ALL AT ALL NOW. I CAN'T PASS INSPECTION WITHOUT IT WORKING.

NHTSA ID
11400135
Incident
Nov 1, 2020
Mileage
165,000 mi
AirbagsBody & structure
Filed Oct 13, 2020
Crash reported1 injury reported

MY SON WAS IN A SIDE IMPACT COLLISION ON THE PASSENGER SIDE OF HIS 2004 VOLVO S60. HE WAS IN A RURAL AREA AND EITHER DIDN'T SEE THE ONCOMING CAR OR MISSED HIS STOP SIGN AND THE ONCOMING DRIVER WAS UNABLE TO STOP. THE OTHER DRIVER IS UNINJURED BUT MY SON IN SEVERELY INJURED WITH A GRADE 3 DAI HEAD INJURY. HE WAS WEARING HIS SEAT BELT. THE SIDE AIRBAGS DEPLOYED BUT NOT THE ONE IN THE STEERING WHEEL. IN AN EMAIL VOLVO TOLD ME THIS IS HOW THE AIRBAGS ARE DESIGNED AND THAT THE DRIVER AIRBAGS WILL NOT DEPLOY ON SIDE IMPACT. IF THAT IS CORRECT INFORMATION, THIS NEEDS TO CHANGE. THE ONLY SIGNIFICANT INJURY MY SON HAS IS WHERE HIS HEAD HIT THE STEERING WHEEL, IF THAT AIRBAG HAD DEPLOYED HIS INJURIES WOULD HAVE POTENTIALLY BEEN MUCH LESS. THE AIRBAGS ARE ALREADY THERE, I DON'T UNDERSTAND WHY THEY CAN'T JUST DEPLOY ON ANY SIGNIFICANT IMPACT. I WILL INCLUDE PICTURES.

NHTSA ID
11364098
Incident
Oct 2, 2020
Mileage
215,000 mi
AirbagsBrakes
Filed Mar 9, 2020
Crash reported

TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED WHILE ATTEMPTING TO MAKE A LEFT TURN, ANOTHER VEHICLE INTERSECTED HER LINE CAUSING IMPACT TO THE FRONT DRIVER'S SIDE. THE AIR BAGS DID NOT DEPLOY. THE CONTACT STATED THAT THE ABS WARNING LIGHT WAS ILLUMINATED PRIOR TO THE ACCIDENT. THE CONTACT STATED NO ONE SUSTAINED INJURIES OR SOUGHT MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS NOT DRIVABLE. THE VEHICLE WAS TOWED TO AN IMPOUND LOT. THE VEHICLE FAILURE HAD NOT BEEN DIAGNOSED OR REPAIRED BY A DEALER OR INDEPENDENT MECHANIC. THE MANUFACTURER HAD NOT BEEN INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 162,000. *LN*JB

NHTSA ID
11317095
Incident
Mar 3, 2020
Mileage
162,000 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

35526.1.8

ENGINE

This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure
 Description and Service sections updated to clarify that vehicle reports are not required.

37809.1.1

This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior approval.
 Current items under prior approval are listed in the "Service" section

19245

This is a Technical Journal. Vehicle type and platform identification.

8501

EXTERIOR LIGHTING

This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session:
 •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between 12.5V and 14.9V.
 •Connect to the vehicle over a wired connection using a VOE (Volvo OBD to Ethernet) adapter and perform a NEW vehicle readout.

S10303

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles.
 Volvo Car Investigations have identified that there is a pairing issue with the key fob.
 As a result, there is a possibility that the customer’s key fob is not paired to the vehicle.
 The corrective action is to download SP Software.
 S10303 affects 151 vehicles in the U.S and 5 in Canada.

S10303

Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles.
 Volvo Car Investigations have identified that there is a pairing issue with the key fob.
 As a result, there is a possibility that the customer’s key fob is not paired to the vehicle.
 The corrective action is to download SP Software.
 S10303 affects 151 vehicles in the U.S and 5 in Canada.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Volvo S60 by model year
YearComplaintsRecallsInvestigationsIssue Index
2025020
2024183060.5
2023360
2022154146.9
2021731
2020104158.0
2019244157.6
2018410
2017155060.5
2016254044.5
2015572051.0
2014253051.1
2013864052.0
20121218057.7
2011560
2010000
2009730
2008102056.5
2007212047.9
2006314043.2
2005444041.1
2004Viewing1986054.0
20031207046.8
20021869255.3
20012239357.4
2000102
1999002
1993000

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.