NHTSA Complaint #10291584 — 2004 VOLVO S60

2004 VOLVO S60 REGULARLY SERVICED BY VOLVO. BOUGHT NEW, WELL MAINTAINED, EXC COND, & OIL CHANGED EVER 3000 MILES. ONLY 68K MILES PRESENTLY BUT MANY PROBLEMS SINCE BOUGHT NEW. #1) REPLACING BURNED OUT REAR/FRONT HEADLIGHT BULBS CONSTANTLY. #2) CHECK ENGINE LIGHT CAME ON BEFORE 40K MILES. WASN'T TOO CONCERNED AT FIRST BECAUSE ONLY ISSUE I SEEMED TO HAVE WAS HESITATION SOMEWHAT WHEN ACCELERATING AFTER BEING PARKED. UNTIL ONE DAY VEH WOULDN'T ACCELERATE BEYOND A ROLL AFTER BEING STOPPED FOR RED LIGHT. A FEW DAYS LATER DRIVING APPROX 50 MPH UPHILL CAR STOPPED ACCELERATING AND STALLED. BOTH TIMES I WAS ABLE TO ROLL TO SIDE OF ROAD, RESTART & MAKE IT HOME. SCARED ME ENOUGH THOUGH TO TAKE TO VOLVO NEXT DAY. FUEL SENSOR GAUGE NEEDED TO BE REPLACED. WHEN I CHECKED IF COVERED UNDER RECALL - FOUND MY CAR WASN'T BASED ON VIN, ANOTHER FAIRLY COSTLY REPAIR. #3 - AC FAN WOULDN'T GO OFF ONE DAY - FAN RUNNING FULL BLAST & CONTROL SWITCH WOULDN'T REGULATE OR WORK. FAN CONTINUED TO RUN EVEN WHEN I TURNED OFF IGNITION. DEAD BATTERY NEXT MORNING NEEDED JUMP START. AC FAN MODULAR BAD - MODULAR REPAIR DONE & THEN FAN SOMEHOW BURNED OUT DUE TO NEW MODULAR WHEN MECHANIC TESTING REPAIR - NOW FAN NEEDED TO BE REPLACED. VERY COSTLY REPAIR ONCE AGAIN. #3 - CHECK ENGINE LIGHT CAME ON. AFTER MONTHS TO SEVERAL MECHANICS, CHECKING OIL, ETC. TOLD LIGHT PROBABLY JUST FAULTY. THEN CHECK OIL LIGHT BLINKS - CAR HAD LESS THAN 1/2 QT OIL & I HAD MAJOR ENGINE DAMAGE. HAD COMPLETE ENGINE REBUILT & VERY EXPENSIVE. ENGINE RUNNING GREAT. NOW 2 MOS LATER & I HEAR A METAL TO METAL NOISE/SOUND WHEN MAKING TURNS - PREFERABLY RIGHT HAND - & COMING FROM RGHT FRONT SIDE OF CAR. MECHANIC CAN'T SEE SAFETY ISSUES WHEN UP ON RACK. HAS NO CLUE. NOISE ANNOYING AND CONCERNING. IT SOUNDS LIKE WHEEL IS GOING TO FALL OFF CAR. I AM SURE IT WILL COST ANOTHER FORTUNE . HOWEVER ONCE REPAIRED - TRADING IN. I LOVED MY CAR...HOWEVER NO LONGER FEEL VEH IS SAFE OR DEPEN. *TR