2004 Volvo S40 problems, complaints & recalls
Most-reported problem areas: Air Bags (5) · Service Brakes, Hydraulic (4) · Vehicle Speed Control (3)
🧭 Reliability snapshot
Compared against other Volvo S40 model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
35 NHTSA complaints that reported an odometer reading.
Safety recalls (1)
Equipment:electrical:navigational System(Global Positioning System) 2010-11-08 · campaign 10V566000 · 416 vehicles
Defect: 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.
Service bulletins (239)
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 239 bulletins. Search all of them free at nhtsa.gov.
What owners report
2020-11-08 · Forward Collision Avoidance: Warnings · 123,713 mi“having a coolant leakage, crash mode and safety alarm system check keeps coming on...when crash mode comes on...car just shuts off.…”
2019-10-01 · Tires · 145,000 mi“tl* the contact owns a 2004 volvo s40 equipped with cooper zeon rs3-a tires, size: 205/55/16r (na). the contact heard a loud humming noise coming from the tires. the inside of the tread had a line and the contact noticed damage or an opening. an independent mechanic confirmed that the tires were separating at the tread line. an unknown tire dealer …”
2018-06-07 · Air Bags · 140,000 mi“no collision. srs light has been coming on since 2007. dealership has replaced wiring, air bags and nothing helps. srs light comes on every 7 to 12 months. this has been going on for 11 years.…”
2018-04-10 · Unknown Or Other“the key does not turn all the way to turn the ignition - it's locked after turning i and ii (not to iii). i had to have the car towed. i could have been stranded in an unsafe area. i called volvo customer service, but i was told it's not under warranty anymore. i went to youtube as to how i could fix it and found out quite a fee s40 owners have…”
2017-01-06 · Exterior Lighting · 140,000 mi“the issue of no headlights (low-bulb failure) is dangerous & expensive. nor is there a viable permanent repair as the "low-bulb failure" always re-occurs & has been an ongoing problem for me since my car was new. suddenly having no headlights causes a serious & immediate safety issue for occupants of the car & for oncoming traffic who can't see a …”
2016-09-23 · Service Brakes · 42,000 mi“brake pedal is too close to accelerator pedal. whenever i operate the gas pedal, the side of my shoe also activates the brake. the problem is aggravated by the center tunnel carpet intruding on the minimal accelerator pedal space.…”
2016-09-05 · Electrical System“my vehicle doors lock up and can't be unlocked due to faulty locks. no way to get door or doors to unlock. which can cause death if involved in a roll over, submerged, or any major accidents. it can be any door on the vehicle. on mine it's my rear passenger door which my child sits next too in her car seat. i've read many other volvos have this iss…”
2016-06-22 · Fuel/Propulsion System · 104,000 mi“car is stalling out while driving down the road engine light came on when put on machine error given is fuel pressure. the fuel pressure was checked and was at correct pressure for the car. i have replaced fuel censer and car ran fine for 2 days then same issue with same error the fuel controller has a corroded pen i tried to call volvo they are…”
2015-11-17 · Service Brakes · 💥 crash“i got new car in nov 2003 of the year 2004 model. it feels like one has to put foot on brakes all the way to apply. it is progressively getting worse. in dec 2005, while existing from highway we meet an accident as it did not stop where it was suppose to stop. volvo dealer top the break fluid during maintenance. but did not solve the problem. we go…”
2015-02-05 · Vehicle Speed Control:accelerator Pedal“tl* the contact owns a 2004 volvo s40. the contact stated that the accelerator pedal and the brake pedal became difficult to depress. also, the contact mentioned that due to the proximity of the pedals, the brake pedal was inadvertently depressed when applying the accelerator pedal. the vehicle was not diagnosed. the manufacturer was notified of th…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.