2001 Volvo S40 Recalls, Problems & Maintenance

The 2001 Volvo S40 has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Premature rear brake pad wear.” Volvo schedules maintenance every 10,000 miles or 12 months, whichever comes first — the cluster's service reminder counts down to it. Drive-E four-cylinder engines (2015+) require Volvo-spec 0W-20; the older five-cylinder turbos (XC70, C30) run on a timing belt with a firm replacement interval, not a chain. AWD Volvos use a Haldex-style rear coupling whose fluid service is the difference between an AWD system that lasts and a four-figure pump-and-clutch repair.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2001 Volvo S40.

Reported to NHTSA

Premature rear brake pad wear

SERVICE BRAKES, HYDRAULIC

9 NHTSA complaints · 2002-05 → 2004-08

“AT 19,600 MILES THE REAR BRAKE PADS WORE OUT ON MY WIFE'S 2001 S40 VOLVO SEDAN. WE WERE TOLD BY THE DEALER THIS IS NORMAL AND THAT THEY HAVE SEEN SOME S40S WEAR THE REAR BRAKES OUT AS EARLY AS 12,000 MILES”
— Owner report, NHTSA ODI #10037199
“THE REAR BRAKE PADS ARE WEARING PREMATURELY AND HAD TO BE REPLACED AT 12500 MILES. THE DEALER SAYS THIS IS TYPICAL OF THIS MODEL, AND THAT THEY ARE TO SMALL. IT COSTS $135 EACH TIME THESE HAVE TO BE REPLACED”
— Owner report, NHTSA ODI #762490
“I HAD MY VOLVO S40 INTO THE DEALER I BOUGHT IT FROM (KEYSTONE, PA) 5 TIMES FOR A SQUEAK IN THE REAR OF THE CAR. EACH TIME WE WERE TOLD THEY COULDN'T LOCATE THE PROBLEM BUT THEY COULD HEAR THE SQUEAK”
— Owner report, NHTSA ODI #10055161

Read all complaints on NHTSA →

Sunroof glass shattering or detachment

VISIBILITY

5 NHTSA complaints · 2001-09 → 2008-08

“WHILE VEHICLE WAS PARKED, THE SUNROOF CAME LOOSE AND FELL INTO THE PASSENGER'S COMPARTMENT. WHEN THIS OCCURRED, GLASS SHATTERED AND SPREAD THROUGHOUT PASSENGER'S COMPARTMENT, DEALERSHIP HAS EXAMINED VEHICLE, AND WAS MAKING NECESSARY REPAIRS”
— Owner report, NHTSA ODI #8003539
“WHILE DRIVING ON A GRATED ROAD, CONSUMERS SON HIT A POTHOLE, AND ALL OF A SUDDEN THE SUNROFF SHATTERED INTO PIECES, DAMAGING THE VEHICLE AS WELL AS ANOTHER MOTORIST VEHICLE.*JB”
— Owner report, NHTSA ODI #562986
“SOMETHING, POSSIBLY A RAIL, FLEW OFF OF MY VOLVO S40 (2001) ON THE HIGHWAY. SUBSEQUENTLY, THE SUNROOF WAS UNABLE TO CLOSE BECAUSE OF GETTING HUNG UP ON THE SUNSHADE. WHEN I BROUGHT IT INTO THE SHOP, I LEARNED THAT THE RAILS WHICH HAD HELD THE SUNROOF IN PLACE”
— Owner report, NHTSA ODI #10236819

Read all complaints on NHTSA →

Loss of brake power assist / vacuum pump failure

SERVICE BRAKES, HYDRAULIC

16 NHTSA complaints · 2001-02 → 2014-11

“TL*THE CONTACT OWNS A 2001 VOLVO S40. WHENEVER THE VEHICLE WAS COLD, THE BRAKES WOULD NOT WORK UNLESS THE PEDAL WAS ENGAGED 6 TIMES. THE DEALER STATED THAT THE BRAKE VACUUM NEEDED TO BE REPLACED. THE FAILURE MILEAGE WAS 63,000. THE CURRENT MILEAGE WAS 74,000”
— Owner report, NHTSA ODI #10312216
“VOLVO MODEL S40 VACUUM BRAKE FAILURE. MY 28 YEAR OLD DAUGHTER WAS MAKING A LOW SPEED TURN AT INTERSECTION AND BRAKES FAILED AND SHE HIT A TELEPHONE POLE. IN 2003 SHE WAS COMING TO A STOP BEHIND ANOTHER CAR AND THE SAME THING HAPPENED”
— Owner report, NHTSA ODI #10052703
“WHEN PRESSING ON THE BRAKE PEDAL CONSUMER HEARD A GRINDING NOISE, CAUSING THE VEHICLE TO HAVE EXTENDED STOPPING DISTANCE. CONSUMER INDICATED THAT THIS PROBLEM ONLY OCCURRED WHEN VEHICLE WAS SHUT OFF FOR ALONG PERIOD OF TIME. *AK”
— Owner report, NHTSA ODI #10068538

Read all complaints on NHTSA →

Unintended acceleration / vehicle speed control failure

VEHICLE SPEED CONTROL

9 NHTSA complaints · 2001-01 → 2012-03

“TL* THE CONTACT OWNS A 2001 VOLVO S40. WHILE ATTEMPTING TO PARK AT APPROXIMATELY 1 MPH, THE VEHICLE SUDDENLY ACCELERATED. THE CONTACT WAS ABLE TO REMOVE THE KEY FROM THE IGNITION TO SHUT THE ENGINE OFF”
— Owner report, NHTSA ODI #10422998
“2001 VOLVO S40 SUDDENLY STARTS ACCELERATING ON ITS OWN REGARDLESS OF THE SPEED I AM TRAVELLING. IT CAN HAPPEN AT SLOW SPEEDS OR HIGHWAY SPEEDS. IT HAPPENS REGARDLESS OF WHETHER THE CRUISE CONTROL IS ON OR OFF”
— Owner report, NHTSA ODI #10396500
“CONSUMER PUT VEHICLE IN DRIVE AND VEHICLE TOOK OFF. CONSUMER HIT A TELEPHONE POLE WHILE TRYING TO AVOID HITTING ANOTHER VEHICLE.*AK”
— Owner report, NHTSA ODI #878201

Read all complaints on NHTSA →

Engine stalling and hesitation

ENGINE AND ENGINE COOLING

11 NHTSA complaints · 2001-07 → 2012-08

“I HAVE A 2001 VOLVO, MODEL S40. DURING THE LAST SIX MONTHS, I'VE EXPERIENCED A STALLED CAR ENGINE -- ESPECIALLY WHEN THE CAR IS IDLING AT A STOP LIGHT. WHEN THE STALL HAPPENS, I MUST FLOOR THE ACCELERATOR TO RESTART THE ENGINE AGAIN”
— Owner report, NHTSA ODI #10131175
“I OWN A 2001 VOLVO S40. IN EARLY APRIL 2005, MY VEHICLE WAS DIAGNOSED AS BEING IN NEED OF OXYGEN SENSORS, WHICH WAS THE REASON FOR MY "CHECK ENGINE" TO BE ACTIVATED. THE PROBLEM IS THAT MY CAR HAD APPROXIMATELY 25,000 MILES ON IT”
— Owner report, NHTSA ODI #10141844
“THE VEHICLE STALLED WHILE DRIVING, VEHICLE WAS TOWED TO THE DEALER, AND THE PROBLEM WAS DETERMINED THAT THE IDLE CONTROL VALVE NEEDE TO BE REPLACED, CONSUMER STATES WHILE DRIVING, VEHICLE STALLED AGAIN AND VEHICLE WAS TOWED TO ANOTHER DEALERSHIP”
— Owner report, NHTSA ODI #561912

Read all complaints on NHTSA →

Engine compartment fire

ENGINE

4 NHTSA complaints · 2001-04 → 2020-07

“CAR CAUGHT FIRE WITHOUT WARNING AS I WAS DRIVING IT. CAR HAD 93,000 AND HAD PASSED VA INSPECTION IN AUGUST. I PULLED OVER AND CALLED 911. BY THE TIME THE FIRE DEPARTMENT ARRIVED 3 MINUTES LATER, ENTIRE ENGINE WAS ENGULFED IN LARGE FLAMES”
— Owner report, NHTSA ODI #10819591
“DRIVING WE SMELLED AN ELECTRICAL TYPE OF SMELL, THEN BELL OWING SMOKE AND THEN WE STOPPED AND TRIED TO OPEN HOOD FIRE CAME GUSHING OUT. CALLED 911 REPORT TO FIRE DEPT. CAR TOTALLED.*AK”
— Owner report, NHTSA ODI #744486
“ME AN MY HUSBAND WAS DRIVING THE CAR AN IT STARTED TO RUN HOT SO WE WENT AN GOT THE PART TO GO ON THE CAR AN WHEN WHEN WE GOT BACK TO MY FATHER IN LAW HOUSE THE CAR CUT OFF AN STARTED TO SMOKE REAL BAD THEN WENT INTO FLAMES”
— Owner report, NHTSA ODI #11339721

Read all complaints on NHTSA →

Airbag deployment failure

AIR BAGS

6 NHTSA complaints · 2002-05 → 2013-08

“TL* THE CONTACT OWNS A 2001 VOLVO S40. THE CONTACT WAS TRAVELING 40 MPH AND CRASHED HEAD-ON INTO ANOTHER VEHICLE. UPON IMPACT, THE AIR BAGS FAILED TO DEPLOY. THE CONTACT SUSTAINED HEAD AND NECK INJURIES. THE POLICE WERE NOTIFIED”
— Owner report, NHTSA ODI #10536050
“CONSUMER'S VEHICLE WAS INVOLVED IN A FRONTAL COLLISION WHILE DRIVING AT 25MPH AND NEITHER AIR BAGS DEPLOYED. DEALER NOTIFIED. *AK”
— Owner report, NHTSA ODI #10022133
“I WAS DRIVING NORTH ON THE GARDEN STATE PARKWAY WHEN THE SIDE CURTAIN AIRBAG ON THE DRIVER'S SIDE OF THE CAR SPONTANEOUSLY DEPLOYED. THE CAR WAS A LEASE THAT I HAD JUST AGREED TO BUY THAT MORNING, SO I CALLED VOLVO CONSUMER AFFAIRS THE NEXT DAY (4/16/04)”
— Owner report, NHTSA ODI #10074974

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter (Annual Service)

Every 10,000 mi

Replace every 10,000 miles or 12 months with Volvo-spec oil (VCC 0W-20 on Drive-E engines). Turbo five-cylinders in the older XC70/C30 are harder on oil — many specialists suggest 7,500 miles on those.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Timing Belt (5-Cylinder — XC70, C30)

Every 105,000 mi

Volvo's five-cylinder engines use a timing belt: replace around 105,000 miles or 10 years (verify your year's exact interval). Interference engine — do the tensioner and idlers in the same job. Drive-E four-cylinders (2015+) use a chain instead.

Estimated cost — typical U.S. ranges

Dealer

~$935–$1175

Shop

~$655–$825

DIY

Pro only

On interference engines, a snapped belt destroys valves. Worth doing on schedule. Bundle water pump + tensioner — labor is already there.

Tire Rotation

Every 10,000 mi

Rotate at every annual service. AWD models: replace tires in matched sets — tread mismatch works the Haldex coupling constantly.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect pads, rotors, and hoses at every service. Heavy XC90s wear front pads quickly in city duty; check electronic parking-brake function on 2016+ models.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 24,000 mi

Replace DOT 4 fluid every 2 years regardless of miles — standard practice for the moisture-absorbing fluid, and cheap insurance for the ABS unit.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

AWD Coupling Fluid (Haldex)

Every 40,000 mi

AWD models: replace the rear coupling's fluid roughly every 40,000 miles (Volvo's published interval varies by generation — check your manual). Skipping it clogs the pump filter and kills the AWD unit; whirring from the rear axle is the classic late symptom.

Estimated cost — typical U.S. ranges

Dealer

~$220–$290

Shop

~$155–$205

DIY

~$40–$90

VW/Audi/Volvo AWD coupling — specific fluid required. Filter usually swapped at the same time.

Automatic Transmission Fluid

Every 60,000 mi

The Aisin 8-speed is labeled long-life, but Volvo specialists broadly recommend fluid service around 60,000 miles — sooner with towing. Use the specified JWS/Toyota WS-type fluid for your gearbox.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Spark Plugs

Every 60,000 mi

Drive-E turbo fours: plugs around every 60,000 miles. Supercharged+turbocharged T6/T8 engines run higher cylinder pressures — don't stretch the interval.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Air Filter

Every 30,000 mi

Replace roughly every 30,000 miles; inspect annually in dusty climates.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 10,000 mi

Volvo specifies frequent cabin-filter replacement — annually on most models, in keeping with the brand's air-quality focus (CleanZone on newer cars).

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Engine Coolant

On condition / lifetime

Volvo long-life coolant typically runs ~10 years on the schedule; refresh with Volvo-spec coolant around 100,000 miles per independent-specialist practice.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

44 crashes 1990–2024

How the 44 occupant deaths break down

33

driver deaths

11

passenger deaths

44

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2001 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

12

complaints mentioning a crash

4

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2001 Volvo S40 reflects Volvo's published service intervals and the Volvo Service Reminder system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.