2004 Volvo S60 Recalls, Problems & Maintenance

The 2004 Volvo S60 has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Fuel pressure sensor failure and recall 07V226 coverage.” 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 2004 Volvo S60.

Reported to NHTSA

Fuel pressure sensor failure and recall 07V226 coverage

ENGINE AND ENGINE COOLING, FUEL SYSTEM, OTHER

60 NHTSA complaints · 2008-02 → 2017-06

“THE ENGINE LIGHT CAME ON IN MY 2004 VOLVO S60. THE CAR WOULD LOOSE ACCELERATION. TOOK IT TO OUR MECHANIC AND HE SAID IT WAS THE FUEL PRESSURE SENSOR AND THAT IT HAD BEEN RECALLED BY VOLVO- RECALL # 07V226000. TOOK IT TO THE DEALER AND THEY SAID THAT THE VIN # OF MY CAR”
— Owner report, NHTSA ODI #10342321
“EXPANSION OF NHTSA CAMPAIGN ID NUMBER 07V226000 ( VOLVO RECALL NO. R181)FOR FUEL PRESSURE SENSOR. HAVE SAME MAKE, MODEL AND YEAR. MANUFACTURE INDICATES MY VIN NOT COVERED. DEALER REPLACED FUEL PRESSURE SENSOR. ERROR CODE ON CAR P0194. DESCRIPTION MATCHES RECALL. *TR”
— Owner report, NHTSA ODI #10334559
“TOOK VEHICLE TO A VOLVO DEALERSHIP FOR A REGULARLY SCHEDULED OIL CHANGE. THE SERVICE ADVISOR REPORTED THAT THE FUEL PRESSURE SENSOR (FPS) IS A CRITICAL COMPONENT, THAT IT FAILED AND NEEDED TO BE REPLACED. HE SAID THAT VOLVO WOULD PAY 50% FOR THE PART AND CHARGE ME THE W”
— Owner report, NHTSA ODI #10375581

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Front tires rubbing against body or frame when turning

TIRES

4 NHTSA complaints · 2006-01 → 2015-01

“FRONT TIRES ARE RUBBING THE BODY ON THE INSIDE OF THE TIRE. VEHICLE HAS ORIGINAL WHEELS AND TIRES. CHRONIC PROBLEM WITH VOLVO. *TR”
— Owner report, NHTSA ODI #10219289
“I AM WRITING ABOUT WHAT MAY BE DESIGN FLAW WITH THE VOLVO S60R THAT HAS ME VERY CONCERNED. MY FRONT TIRES RUB ON THE BODY IN THE WHEEL WELL WHEN I TURN SHARPLY INTO A PARKING SPACE. I DON'T THINK IT SHOULD DO THAT BUT I'VE BEEN TOLD IT'S "NORMAL" AND THE CAR "SETTLES" A”
— Owner report, NHTSA ODI #10681259
“DT*: THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS AND TURNING LEFT OR RIGHT THE TIRES TOUCHES THE FRAME OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION ON FOUR OCCASIONS. THE FIRST TIME THE DEALER PLACED STEERING BLOCKS ON THE VEHICLE. THE SECON”
— Owner report, NHTSA ODI #10149150

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Engine stalling or loss of power while driving

ENGINE AND ENGINE COOLING

99 NHTSA complaints · 2005-08 → 2017-09

“THE CONTACT OWNS A 2004 VOLVO S60. WHILE DRIVING LESS THAN 50 MPH AND SLOWING DOWN TO MAKE A TURN, THE VEHICLE STALLED. THIS BECAME A PATTERN WHEN ATTEMPTING TO MAKE LEFT AND RIGHT TURNS. THE DEALER STATED THAT THERE WAS A RECALL FOR THE FAILURE; HOWEVER, HIS VIN WAS NO”
— Owner report, NHTSA ODI #10253603
“NUMEROUS TIMES VEHICLE HAS STALLED SUDDENLY AT VARIOUS SPEEDS - ALL POWER IS LOST AND THE CHECK ENGINE LIGHT IS ILLUMINATED. VEHICLE WILL RESTART AFTER A FEW MINUTES. TAKEN TO LOCAL MECHANIC - UNABLE TO REPLICATE ISSUE. FOUND RECALL FOR 2004 VOLVO S60, BUT VEHICLE VIN N”
— Owner report, NHTSA ODI #10406252
“I HAVE A 2004 VOLVO S-60 WITH APPROXIMATELY 75,000 MILES ON IT. IN THE PAST 6 WEEKS, THE CAR ENGINE HAS COMPLETELY DIED THREE SEPARATE TIMES - WITHOUT WARNING. *TR THE EMERGENCY HAZARD LIGHT STILL WORKED, THE FAN STILL BLOWS (NO A/C, JUST THE FAN), BUT OTHERWISE THERE I”
— Owner report, NHTSA ODI #10353108

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Fuel leak, fuel odor and fuel fill overflow

FUEL SYSTEM, GASOLINE

12 NHTSA complaints · 2007-11 → 2022-11

“I HAD MY CAR IN FOR SERVICE AT MY LOCAL VOLVO REPAIR SHOP AND ONE OF THE ITEMS I HAD THEM INVESTIGATE WAS A FUEL SMELL. THEY TOLD ME THEY FOUND A CRACK AT FUEL PUMP SENDER RH SIDE. THEY MENTIONED THAT THEY THOUGHT THERE WAS A RECALL FOR THIS SINCE THEY HAVE SEEN IT SEVE”
— Owner report, NHTSA ODI #10574239
“WHILE FUELING THE VEHICLE, GASOLINE BUBBLES UP AND OUT THROUGH THE FILLER NECK, LEAVING A LARGE PUDDLE OF GASOLINE ON THE GROUND. THIS GENERALLY HAPPENS WHEN THE TANK IS LESS THAN HALF FULL. *TR”
— Owner report, NHTSA ODI #10225299
“STRONG FUEL ODOR EMITTING FROM PASSENGER SIDE OF VEHICLE. OBSERVED GAS STAINS COVERING OUTSIDE OF GAS TANK. RETURNED TO DEALER AND DEALER REPLACED FUEL PUMP. SINCE THEN, NO ODORS. HOWEVER, AUTO CONTINUES TO HESITATE WHEN DRIVING. IN ONE INSTANCE, CAR STALLED IN HEAVY TR”
— Owner report, NHTSA ODI #10208579

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Heated seat overheating, smoke or burning

SEATS

11 NHTSA complaints · 2010-12 → 2021-04

“THE DRIVER SEAT OVERHEATED, APPARENTLY FROM A MALFUNCTIONING SEAT WARMER, CAUSING COMBUSTION. THE FIRE BURNED THROUGH THE SEAT PADDING, OUTER LEATHER COVERING, AND THE DRIVER'S CLOTHING. IT BURNED INTO A WALLET IN THE DRIVER'S BACK POCKET, WHICH PROTECTED THE DRIVER FRO”
— Owner report, NHTSA ODI #10500970
“BURNING PASSENGER SEAT IN 2004 VOLVO S60R. WHILE DRIVING I SMELT A HORRIBLE BURNING SMELL AND SEEN SMOKE COMING FROM THE PASSENGER SEAT WHICH EVENTUALLY STARTED A FIRE. I TURNED OFF THE HEATED SEATS AND NOW HAVE A BURN ABOUT AN INCH IN DIAMETER. THIS IS VERY DANGEROUS A”
— Owner report, NHTSA ODI #10392822
“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 NOT”
— Owner report, NHTSA ODI #11406424

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Tire blowout, bubble or tread separation

TIRES

6 NHTSA complaints · 2004-10 → 2010-01

“DELAMINATION OF BRIDGESTONE BLIZZAK 15 INCH SNOW TIRE AT HIGHWAY SPEED, REAR LEFT TIRE. NO INJURY OR DAMAGE BUT TIRE TREAD COMPLETELY SEPARATED FROM SIDEWALL AS ONE UNIT LIKE A DONUT. 1 YEAR OLD TIRES WITH LESS THAN 10,000 MILES. *TR”
— Owner report, NHTSA ODI #10300051
“I OWN A VOLVO S60 AND HAVE UNDER 30,000 MILES ON THE VEHICLE. YESTERDAY I SUFFEREDTHE SECOND BLOW OUT ON THE CONTINENTAL CONTITOURING CONTACT TIRES, 215/55R16 93H CH95. I AM CONCERNED FOR MY SAFETY AND THE SAFETY OF OTHERS AS THESE TIRES APPEAR TO BE DEFECTIVE WITH TWO”
— Owner report, NHTSA ODI #10196178
“BOUGHT VOLVO S60 AWD FROM VOLVO OF DANBURY JULY 2004. SEPTEMBER 1, 2004 NOTICED A BUBLE ON THE REAR DRIVERS SIDE TIRE. ON 10/25/2004 MY WIFE HAD A BLOW OUT ON I84 ON THE FRONT DRIVERS SIDE TIRE WHILE DRIVING ON A NEWLY PAVED HIGHWAY ROAD. NEARLY INJURING HERSELF AND CAR”
— Owner report, NHTSA ODI #10096351

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Vehicle lurching or accelerating unexpectedly at low speed

VEHICLE SPEED CONTROL

4 NHTSA complaints · 2007-02 → 2011-04

“WHEN PULLING INTO A PARKING SPACE AT MY DAUGHTER'S SCHOOL, VEHICLE SUDDENLY ACCELERATED OVER THE SIDEWALK AND STRUCK THE BUILDING. TRANSMISSION POPPED IN REVERSE AND VEHICLE ACCELERATED BACKWARDS. EVEN WITH THE BRAKE PEDAL ALL THE WAY TO THE FLOOR, VEHICLE WOULD NOT STO”
— Owner report, NHTSA ODI #10348425
“I WAS LEAVING UCLA PARKING GARAGE (I'M AN RN THERE) WHEN I PUT MY VOLVO 2004 S60 INTO GEAR AND IT TOOK OFF BACKWARDS LIKE A ROCKET, CAR WAS THROWN INTO A CONCRETE POST FAR AWAY FROM WHERE I BEGAN. I IMMEDIATELY PUT CAR IN PARK SINCE I THOUGHT I'D GET OUT AND SEE WHAT ON”
— Owner report, NHTSA ODI #10219547
“TL*- WHILE PARKING THE 2004 VOLVO S60 IN THE DRIVEWAY THE VEHICLE SUDDENLY LURCHED FORWARD, CAUSING THE FRONT WHEELS TO GO OVER A CEMENT BLOCK, HITTING THE HOUSE LIGHTLY. SMOKE STARTED COMING FROM THE ENGINE, AND THE SERVICE ENGINE LIGHT ILLUMINATED ON THE DASHBOARD. TH”
— Owner report, NHTSA ODI #10183806

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)

38 crashes 1990–2024

How the 38 occupant deaths break down

31

driver deaths

7

passenger deaths

38

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2005 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

12

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 2004 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.