2004 Volvo S60 problems, complaints & recalls
Most-reported problem areas: Engine And Engine Cooling (39) · Fuel System, Gasoline (20) · Fuel/Propulsion System (15)
🧭 Reliability snapshot
Compared against other Volvo S60 model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
172 NHTSA complaints that reported an odometer reading.
Safety recalls (2)
Air Bags:frontal:driver Side:inflator Module 2021-09-30 · campaign 21V766000 · 259,383 vehicles
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.
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.
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 (181)
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 181 bulletins. Search all of them free at nhtsa.gov.
What owners report
2024-07-08 · Engine“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 ru…”
2022-11-30 · Fuel/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…”
2021-11-22 · Electrical System: Instrument Cluster/Panel · 157,000 mi“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 …”
2021-10-21 · Fuel/Propulsion System“recall airbags- fuel gauge goes up and down never registers correctly…”
2021-04-05 · Seats · 107,000 mi · 🔥 fire“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 close…”
2021-03-10 · Seat Belts · 165,000 mi“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.…”
2020-10-13 · Structure:body · 215,000 mi · 💥 crash“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 airba…”
2020-03-09 · Service Brakes, Air:antilock:abs Warning Light · 162,000 mi · 💥 crash“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 medic…”
2018-11-01 · Engine · 30,000 mi · 🔥 fire“tl* the contact owns a 2004 volvo s60. the contact stated that while stationary, the engine caught fire. the contact stated that smoke entered into the cabin of the vehicle. the contact exited the vehicle and opened the hood, and the engine was surrounded by flames. a police or fire department report was not filed. an independent mechanic extinguis…”
2018-01-25 · Seats · 155,000 mi · 🔥 fire“heated seat shorted when turned on on drivers side and burned me while driving.…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.