Wrench.Pro

2002 Volvo S60 Recalls, Problems & Maintenance

The 2002 Volvo S60 has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Fuel pump and fuel tank leaks with fuel odor.” 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.

Save this car as:

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 2002 Volvo S60.

Reported to NHTSA

Fuel pump and fuel tank leaks with fuel odor

FUEL SYSTEM, GASOLINE

60 NHTSA complaints · 2007-09 → 2018-10

“TOOK VEHICLE IN QUESTION TO MY MECHANIC DUE TO STARTING ISSUE AND FUEL SMELL. HE DIAGNOSED A SIGNIFICANT FUEL LEAK DUE TO A CRACKED FLANGE ON THE FUEL PUMP”
— Owner report, NHTSA ODI #10534308
“I JUST BOUGHT A 2002 VOLVO S60 ABOUT THREE MONTHS AGO, AND I'VE NOTICED A STRONG FUEL SMELL IN AND AROUND CAR. THERE IS A LEAK IN THE FUEL PUMP AND WHEN CAR IS PARKED, FUEL FORMS A PUDDLE UNDER CAR”
— Owner report, NHTSA ODI #10476836
“THE CONTACT STATED THAT WITHOUT WARNING FUEL STARTED LEAKING FROM THE FUEL TANK”
— Owner report, NHTSA ODI #10700642

Read all complaints on NHTSA →

Throttle module limp mode and loss of acceleration

VEHICLE SPEED CONTROL

30 NHTSA complaints · 2003-11 → 2022-06

“WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE WENT INTO LIMP MODE AND FAILED TO ACCELERATE OVER 30 MPH”
— Owner report, NHTSA ODI #10651045
“THE CONTACT STATED THAT WHILE DRIVING 60 MPH THE VEHICLE WOULD GO INTO LIMP MODE AND DECELERATE TO 15 MPH UNEXPECTEDLY. THE FAILURE RECURRED ON AN INTERMITTENT BASIS”
— Owner report, NHTSA ODI #10413572
“I WAS DRIVING MY CAR YESTERDAY AUGUST 4TH, 2005 AND ALL OF A SUDDEN THE ACCELERATOR WOULD NOT WORK. I WAS IN THE MIDDLE OF AN INTERSECTION AND HAD TO COAST THE CAR TO THE SHOULDER OF THE ROAD”
— Owner report, NHTSA ODI #10131692

Read all complaints on NHTSA →

Tire sidewall bubbles, separation and blowouts

TIRES

13 NHTSA complaints · 2002-04 → 2008-08

“ALL THREE FAILURES WERE ON THE SIDEWALL OF THE TIRE AND NONE COULD BE REPAIRED”
— Owner report, NHTSA ODI #10087042
“BACK IN JANUARY I HAD A BLOWOUT AFTER HITTING A BUMP IN THE ROAD. NOW THE 3 REMAINING TIRES HAVE DEVELOPED LARGE BUBBLES IN THE SIDEWALLS. ALL 4 OF MY RIMS ARE BENT”
— Owner report, NHTSA ODI #10036611
“TIRE BUBBLE DEVELOPED ON SIDEWALL OF TIRE WITHOUT ANY IMPACT. CAR TAKEN TO DEALER FOR REVIEW AND SERVICE MANAGER SAID THIS WAS A SAFETY ISSUE AND TIRE NEEDED TO BE REPLACED”
— Owner report, NHTSA ODI #761050

Read all complaints on NHTSA →

Automatic transmission shift flare, slip and clunking

POWER TRAIN

5 NHTSA complaints · 2004-01 → 2014-08

“THE CAR CONTINUES TO HAVE SHIFT FLARES AND SLIPPAGE WHEN SHIFTING UP FROM 1 TO 2, 2 TO 3 OR SHIFTING BETWEEN THE SAME GEARS”
— Owner report, NHTSA ODI #10627527
“WHILE CAR SHIFTS AUTOMATICALLY FROM GEAR TO GEAR THE ENGINE WILL RACE AND THE TACHOMETER NEEDLE WILL JUMP. THE CAR WILL LURCH FORWARD ONCE THE GEAR FINALLY CATCHES”
— Owner report, NHTSA ODI #10052930
“2002 VOLVO S60 - TRANSMISSION CLUNKS WHEN ENGAGING GEAR IN DRIVE”
— Owner report, NHTSA ODI #10394435

Read all complaints on NHTSA →

Instrument cluster (driver information module) failure

ELECTRICAL SYSTEM

9 NHTSA complaints · 2010-06 → 2017-08

“ON A 2002 VOLVO S60, THE DRIVER'S INFORMATION MODULE INTERMITTENTLY BLANKS OUT RENDERING THE VEHICLE WITH NO SPEEDOMETER AND FUEL GAUGE”
— Owner report, NHTSA ODI #10380976
“WHILE THE VEHICLE WAS IN PARK, THE CONTACT NOTICED THAT THE GAUGES, METERS, AND LIGHTS ON THE INSTRUMENT CLUSTER FAILED TO FUNCTION”
— Owner report, NHTSA ODI #10853251
“INSTRUMENT CLUSTER (KNOWN AS DRIVER INFORMATION MODULE) COMPLETELY DIED WHILE DRIVING”
— Owner report, NHTSA ODI #10434247

Read all complaints on NHTSA →

Air bag recall repair availability and inflator complaints

AIR BAGS

4 NHTSA complaints · 2021-02 → 2022-06

“CONSUMER WRITES IN REGARDS TO NHTSA SAFETY RECALL 21V-766. THE CONSUMER STATED THERE WERE NO VOLVO DEALERSHIPS WITHIN A REASONABLE DISTANCE TO PERFORM THE REPAIR”
— Owner report, NHTSA ODI #11458708
“The contact received a recall notification for NHTSA Campaign Number: 21V766000 (Air bags) however, the part to do the recall repair was not yet available”
— Owner report, NHTSA ODI #11449962
“AIR BAG THROW SHARDS OF METAL BUT VOLVO SAY I SHOULDN'T DRIVE IT BUT WON'T GIVE LOANER CAR, THEY WON'T HELP US AT ALL WITH THE SITUATION”
— Owner report, NHTSA ODI #11398126

Read all complaints on NHTSA →

Issues on other model years

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

40

driver deaths

4

passenger deaths

44

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2002 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.

4

complaints mentioning a crash

3

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 2002 Volvo S60 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.

Check another vehicle →