The 2004 Volvo S60 has 6 safety recalls and 198 owner complaints on file with NHTSA. The most-reported problem area is engine and engine cooling (63 complaints).
Recalls6safety recalls
Complaints198filed by owners
Crashes · fires12 · 12reported in complaints
Injuries · deaths8 · 0reported in complaints
2004 Volvo S60 in an NHTSA crash test
Safety recalls
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.
NHTSA recall 10V566000 · Nov 8, 2010 · 416 vehicles
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
NHTSA recall 09V483000 · Dec 18, 2009 · 158,733 vehicles · opened after NHTSA action (ODI)
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
NHTSA recall 07V226000 · Jun 5, 2007 · 32,189 vehicles
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.
Service brakes, hydraulic › Foundation components › Master cylinder
NHTSA recall 07E023000 · Mar 29, 2007 · 13,128 vehicles
Problem: 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.
Risk: LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH.
Fix: 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.
Steering › Linkages
NHTSA recall 04V029000 · Jan 16, 2004 · 29,986 vehicles
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.
Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.
Crash test ratings
2004 Volvo S60 4-DR. w/SAB
Overall
Not Rated
Frontal crash
Not Rated
Side crash
Not Rated
Rollover
★★★★★
Rollover risk
9.3%
NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.
Fuel economy
S60 FWD
22mpg combined
City / highway
19 / 28 mpg
Fuel
Premium Gasoline
2.4 L · 5 cyl · Automatic 5-spd · Front-Wheel Drive · about $3,750/year to fuel
S60 FWD
22mpg combined
City / highway
19 / 27 mpg
Fuel
Premium Gasoline
2.4 L · 5 cyl · Manual 5-spd · Front-Wheel Drive · about $3,750/year to fuel
S60 FWD
22mpg combined
City / highway
19 / 27 mpg
Fuel
Premium Gasoline
2.5 L · 5 cyl · Automatic 5-spd · Front-Wheel Drive · about $3,750/year to fuel
S60 FWD
21mpg combined
City / highway
18 / 25 mpg
Fuel
Premium Gasoline
2.3 L · 5 cyl · Manual 5-spd · Front-Wheel Drive · about $3,900/year to fuel
S60 FWD
21mpg combined
City / highway
18 / 26 mpg
Fuel
Premium Gasoline
2.3 L · 5 cyl · Automatic (S5) · Front-Wheel Drive · about $3,900/year to fuel
S60 AWD
20mpg combined
City / highway
18 / 25 mpg
Fuel
Premium Gasoline
2.5 L · 5 cyl · Automatic 5-spd · 4-Wheel or All-Wheel Drive · about $4,100/year to fuel
S60 R AWD
19mpg combined
City / highway
16 / 23 mpg
Fuel
Premium Gasoline
2.5 L · 5 cyl · Manual 6-spd · 4-Wheel or All-Wheel Drive · about $4,350/year to fuel
S60 R AWD
19mpg combined
City / highway
16 / 23 mpg
Fuel
Premium Gasoline
2.5 L · 5 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $4,350/year to fuel
EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.
What owners report
Problem area
Complaints
Crashes
Fires
Injuries
Typical mileage*
Engine and engine cooling Engine; Cooling system
63
3
0
1
78,622 mi
Fuel system, gasoline Delivery › Fuel pump; Fuel injection system
30
1
0
1
77,000 mi
Engine
22
0
1
0
106,000 mi
Electrical system Ignition; Instrument cluster/panel
21
0
4
0
101,165 mi
Fuel/propulsion system
18
0
0
0
121,500 mi
Seats Front assembly › Seat heater/cooler; Front assembly › Power adjust
13
0
10
1
107,000 mi
Power train Automatic transmission; Automatic transmission › Lever and linkage › Floor shift
12
1
0
1
30,000 mi
Vehicle speed control Cables
11
3
0
0
92,058 mi
Air bags Side/window; Frontal
10
7
0
6
76,500 mi
Tires Sidewall
9
0
0
0
27,250 mi
Steering
9
0
0
0
100,000 mi
Exterior lighting Headlights
7
0
0
0
82,927 mi
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
Jul 8, 2024Air bags 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.
Nov 27, 2022Fuel/propulsion system 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…
Apr 1, 2021 · 157,000 milesElectrical system › Instrument cluster/panel 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.
Mar 20, 2020Air bags RECALL AIRBAGS- FUEL GAUGE GOES UP AND DOWN NEVER REGISTERS CORRECTLY
Mar 7, 2021 · 107,000 miles · fireSeats 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.
Nov 1, 2020 · 165,000 milesSeat belts 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.
Oct 2, 2020 · 215,000 miles · crash · 1 injuryAir bags 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…
Mar 3, 2020 · 162,000 miles · crashAir bags 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
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.
