2002 Volvo S40 problems, complaints & recalls
Most-reported problem areas: Exterior Lighting:headlights (2) · Engine And Engine Cooling (2) · Electrical System (2)
🧭 Reliability snapshot
Compared against other Volvo S40 model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (157)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Engine 2026-04-23 · 35526.1.8 · Service Bulletin/Repair Instructions
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.
Unknown Or Other 2026-04-07 · 37809.1.1 · Service Bulletin/Repair Instructions
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" sec
Unknown Or Other 2025-12-06 · 19245 · Service Bulletin/Repair Instructions
this is a technical journal. vehicle type and platform identification.
Exterior Lighting 2025-04-10 · 8501 · Service Bulletin/Repair Instructions
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
Unknown Or Other 2025-02-21 · S10303 · Service Campaign
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 possibil
Unknown Or Other 2025-02-13 · S10303 · Service Campaign
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 possibil
Showing the 6 most recent of 157 bulletins. Search all of them free at nhtsa.gov.
What owners report
2017-12-21 · Fuel/Propulsion System · 130,000 mi“tl* the contact owns a 2002 volvo s40. the contact inquired about getting her vehicle included in an open recall. the contact stated that there was a delay when the accelerator pedal was depressed. the contact also stated that she observed a fuel odor inside the vehicle and she was concerned of a fuel leak. in addition, the check engine indicator i…”
2013-11-03 · Service Brakes · 145,000 mi“i was driving on a main road and my brakes failed. it was determined that a brake line corroded through. it appears that the vehicle has a single master brake cylinder. i asked a volvo dealership about this, and they confirmed to me that the master brake cylinder is a single one. it is my understanding that in the 80's, all vehicles sold in the…”
2013-01-03 · Suspension · 114,800 mi“while driving the right front and right rear coil springs broke and the front coil spring damaged the tire. dealer stocks these expensive springs (both front and rear) in larger than normal amounts due to incidences of breakage. i feel that this was an early failure for this type and age of vehicle and should it have been a a higher speed the inci…”
2011-09-07 · Service Brakes, Hydraulic:power Assist:vacuum:hoses, Lines/Piping, And Fittings · 150,000 mi“tl* the contact owns a 2002 volvo s40. the contact stated that the brakes were applied while reversing and the pedal traveled to the floorboard abnormally. the contact took the vehicle to a local mechanic where the mechanic advised that there was a crack in the master cylinder. the master cylinder was replaced however, the failure recurred while i…”
2011-01-07 · Service Brakes, Hydraulic · 104,000 mi · 💥 crash“tl*the contact owns a 2002 volvo s40. while driving 30 mph the contact engaged the brakes when the vehicle in front of her slowed down causing a crash. the vehicle failed to slow down when the brakes were applied. the contact was not injured. a police report was filed. the contacts vehicle had front end damages. the vehicle was repaired. the contac…”
2009-07-11 · Suspension:front“front end suspension isn't right,pulls when driving and there is a knocking items nhtsa 10016415 and 630879. check engine has always been on 10003441. there is a clunking noise when shifting 10003398. there was never an accident these are just ongoing things and the suspension may cause an accident and check engine light is hard to get passed for i…”
2007-12-08 · Suspension:rear:springs · 40,000 mi“both rear springs broke, vehicle had less then 40k miles. *tr…”
2007-06-27 · Power Train:automatic Transmission · 42,000 mi“tl*the contact owns a 2002 volvo s40. the vehicle hesitated when it was started by the contact. the winter weather driving warning indicator arrow and the check engine light illuminated while driving 5 mph. the check engine light remained illuminated after turning the vehicle on an off. on june 23, 2007, the dealer advised the contact not to dr…”
2007-05-22 · Visibility:power Window Devices And Controls · 2,000 mi“types of recurring issues with volvo s40: headlights, driver front window motor, early brake pad wear. headlight bulbs were replaced 2-3 times a year at consumer's cost. when brought to the attention of volvo dealer they reported that it was probably due to lights being used during daylight. they check electrical and reported no issue. had brak…”
2007-02-15 · Electrical System:wiring · 30,000 mi“tl*- the contact stated that while attempting to drive the 2002 volvo s40 he turned the key in the ignition and a thick black smoke came from the front driver side door panel and filled the interior of the vehicle immediately. the contact turned the vehicle off and exited the vehicle. the vehicle was taken to a volvo dealer and they could not fi…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.