2004 VOLVO S60 — Problems, Recalls & Safety Data
N/A
Safety Rating
262
Owner Complaints
6
Recalls
4
Service Bulletins
0
Investigations
Overview of the 2004 VOLVO S60
The 2004 VOLVO S60 has received a total of 262 safety complaints filed with the National Highway Traffic Safety Administration (NHTSA). There have been 6 recall campaigns affecting this vehicle, covering issues with AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE, EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM), FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP. 4 technical service bulletins have been issued by Volvo Car USA, LLC for this model year. The most commonly reported problems involve the Engine And Engine Cooling (49 complaints), Engine (22 complaints), and Fuel System Gasoline (22 complaints).
Recalls for the 2004 VOLVO S60
NHTSA has recorded 6 recalls for the 2004 VOLVO S60, potentially affecting up to 493,835 vehicles.
Recall 21V766000 — AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
| 259,383 vehicles affected
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.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
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.
View full details →Recall 10V566000 — EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)
| 416 vehicles affected
Defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
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...
View full details →Recall 09V483000 — FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
| 158,733 vehicles affected
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...
Consequence: 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.
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....
View full details →Recall 07V226000 — ENGINE AND ENGINE COOLING
| 32,189 vehicles affected
Defect: 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...
Consequence: 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.
Remedy: 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.
View full details →Recall 07E023000 — SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
| 13,128 vehicles affected
Defect: CERTAIN CARDONE MASTER CYLINDERS WITH PART NUMBERS 10-2925, 10-2987, 10-2987MZA, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, AND 11-3156, AND WITH DATE CODES LOWER THAN DCA7078 SOLD AS REPLACEMENT EQUIPMENT FOR USE ON THE VEHICLES LISTED ABOVE. THE SEAL ON MASTER CYLINDER CAN FAIL AND LEAK BRAKE FLUID.
Consequence: LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: CARDONE WILL NOTIFY OWNERS AND OFFER TO REPURCHASE ANY DEFECTIVE MASTER CYLINDERS. THE RECALL BEGAN DURING APRIL 2007. OWNERS CAN CONTACT CARDONE AT 1-800-777-4780.
View full details →Recall 04V029000 — STEERING:LINKAGES
| 29,986 vehicles affected
Defect: 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.
Consequence: THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.
Remedy: 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.
View full details →Owner Complaints for the 2004 VOLVO S60
262 complaints have been filed with NHTSA for the 2004 VOLVO S60. Below is a breakdown by vehicle component.
Most Recent Complaints
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.
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.
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.
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)
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.
Safety Rating for the 2004 VOLVO S60
NHTSA has not yet tested the 2004 VOLVO S60 in its New Car Assessment Program.
Technical Service Bulletins for the 2004 VOLVO S60
Volvo Car USA, LLC has issued 4 technical service bulletins (TSBs) for the 2004 VOLVO S60. TSBs are notices sent by manufacturers to their dealers describing a known issue and the recommended repair procedure.
TJ-US16761 — POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)
VOLVO: THERE IS A SOFTWARE UPDATE. *RM UPDATED 4/11/2012. *KB UPDATED 4/13/12. *PE UPDATED 5/15/12. *PE UPDATED 6/4/12. *PE
4349 — POWER TRAIN:AUTOMATIC TRANSMISSION
AW55 TRANSMISSION CONTROL MODULE DIAGNOSTIC TROUBLE CODE 010A, 010B, 010C SHIFT SOLENOID S5 SIGNAL LOW, HIGH OR MISSING. *AK
6420 — STEERING:ELECTRIC POWER ASSIST SYSTEM
ZF POWER STEERING DIAGNOSTICS ON VEHICLES EQUIPPED (ECPS) ELECTRONICALLY CONTROLLED POWER STEERING. *TT
0013 — SUSPENSION:FRONT:CONTROL ARM
BALL JOINT (SEMS) NUT SECURING THE FRONT CONTROL ARM TO THE SPINDLE MAY LOSE ITS INITIAL TENSION. *TT
NHTSA Investigations for the 2004 VOLVO S60
There are no NHTSA defect investigations on record for this vehicle.
Other Model Years of the VOLVO S60
- 2000 VOLVO S60 — 1 complaint
- 2001 VOLVO S60 — 262 complaints
- 2002 VOLVO S60 — 248 complaints
- 2003 VOLVO S60 — 168 complaints
- 2004 VOLVO S60 (current)
- 2005 VOLVO S60 — 57 complaints
- 2006 VOLVO S60 — 42 complaints
- 2007 VOLVO S60 — 34 complaints
- 2008 VOLVO S60 — 14 complaints
- 2009 VOLVO S60 — 9 complaints
Other VOLVO Models
- VOLVO XC90 — 2,131 total complaints
- VOLVO S80 — 1,320 total complaints
- VOLVO V70 — 1,177 total complaints
- VOLVO XC60 — 846 total complaints
- VOLVO S70 — 780 total complaints
- VOLVO 850 — 732 total complaints
- VOLVO S40 — 677 total complaints
- VOLVO V70XC — 521 total complaints