2006 Volvo S40 Recalls, Problems & Maintenance

The 2006 Volvo S40 has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Sunroof glass spontaneous shattering.” 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 2006 Volvo S40.

Reported to NHTSA

Sunroof glass spontaneous shattering

VISIBILITY

3 NHTSA complaints · 2009-02 → 2013-11

“CAR WAS PARKED IN THE DRIVEWAY AT MY HOUSE OVERNIGHT. WHEN I OPENED THE DRIVER'S DOOR TODAY MID-DAY, I SAW GLASS ALL OVER THE FRONT SEATS. THE SUNROOF HAD EXPLODED UPWARD. THE EDGES OF THE GLASS STILL REMAINING IN THE SUNROOF ARE CLEARLY PUSHED UP AND OUTWARD, NOT DOWNWARD INTO”
— Owner report, NHTSA ODI #10551542
“TL*THE CONTACT OWNS A 2006 VOLVO S40. WHILE DRIVING 65 MPH, THE SUN ROOF SPONTANEOUSLY SHATTERED. AS A RESULT, GLASS SHATTERED IN SMALL PIECES ALL OVER THE INTERIOR OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER, BUT THEY COULD NOT DETERMINE THE CAUSE OF THE FAILURE. THE”
— Owner report, NHTSA ODI #10257689
“SPONTANEOUS ERUPTION( SHATTERING) OF A SUNROOF. *TR”
— Owner report, NHTSA ODI #10257684

Read all complaints on NHTSA →

Accelerator and brake pedal proximity

STRUCTURE

3 NHTSA complaints · 2006-05 → 2008-03

“THE PROXIMITY OF THE GAS & BRAKE PEDAL IS A POTENTIAL PROBLEM THAT NEEDS TO BE ADDRESSED. THIS OBVIOUS PROBLEM WAS EVIDENT THE VERY FIRST TIME I DROVE THE CAR. REGULAR SNEAKERS ARE NOTICED, BUT IS COMPOUNDED WHEN IN WORK STYLE BOOTS. PLEASE RESEARCH THIS- *TR”
— Owner report, NHTSA ODI #10222643
“DT*: THE CONTACT STATED THE ACCELERATOR AND BRAKE PEDAL ARE TOO CLOSE TOGETHER. THE VEHICLE HAS NOT BEEN INSPECTED BY THE DEALERSHIP”
— Owner report, NHTSA ODI #10158706
“THE BRAKE PEDAL AND GAS PEDAL ON MY 2006 VOLVO S40 ARE TOO CLOSE TOGETHER. *TR”
— Owner report, NHTSA ODI #10207369

Read all complaints on NHTSA →

Reduced front brake power and brake noise

SERVICE BRAKES, HYDRAULIC

2 NHTSA complaints · 2006-10 → 2007-10

“NOTICED REDUCED BRAKING POWER AND BRAKES SQUEALING. TOOK VEHICLE TO DEALERSHIP REPAIR FACILITY FOR INSPECTION. BRAKES WERE FOUND TO BE "DISENGAGED" ON THE PASSENGERS SIDE FRONT AND "PARTIALLY FUNCTIONAL" ON DRIVERS SIDE FRONT. NO BRAKE WARNING LIGHT WAS DISPLAYED ON DASH. BRAKE”
— Owner report, NHTSA ODI #10207310
“PROBLEM WITH BRAKES ON 2006 VOLVO S40 T5. SEVERE SCREACHING NOISE COMES FROM BRAKES WHEN IN REVERSE. VOLVO IS AWARE OF THE PROBLEM YET THEY HAVE NOT BEEN ABLE TO RESOLVE THE ISSUE. MY VOLVO S40 HAS HAD BRAKE PARTS REPLACED 4 TIMES. EACH TIME I WAS TOLD THE PROBLEM WAS FIXED. ONE”
— Owner report, NHTSA ODI #10171109

Read all complaints on NHTSA →

Fuel pump and pump electronic module stall or no-start

FUEL/PROPULSION SYSTEM

10 NHTSA complaints · 2010-08 → 2022-08

“Check engine light came on and has stayed on. Stalled out in traffic, turned the car off and it restarted and I continued. Happens two more times. Initial start up has a delay in the engine turning over. Gas pedal is slow to respond to acceleration. Verified at a garage with”
— Owner report, NHTSA ODI #11470947
“TL*THE CONTACT OWNS A 2006 VOLVO S40. THE CONTACT WAS DRIVING UP AN INCLINE AT APPROXIMATELY 35 MPH, THE ENGINE REVVED EXCESSIVELY AND BEGAN TO BUCK. SUDDENLY THE ENGINE STALLED AND RESTARTED. THE VEHICLE RESUMED FOR FIFTEEN SECONDS BEFORE THE FAILURE RECURRED. THE FAILURE WOULD”
— Owner report, NHTSA ODI #10352696
“TL* THE CONTACT OWNS A 2006 VOLVO S40. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSIS WHERE IT WAS STATED THAT THE FUEL PUMP AND PUMP ELECTRONIC MODULE (PEM) NEEDED TO BE REPAIRED. THE DEALER ALSO INFORMED THE CONTACT THAT”
— Owner report, NHTSA ODI #10538515

Read all complaints on NHTSA →

Electrical warning-light cascade and instrument shutdown

ELECTRICAL SYSTEM

15 NHTSA complaints · 2007-08 → 2016-01

“WHILST DRIVING, THE INSTRUMENTS ON THE INSTRUMENT CLUSTER DROPPED TO ZERO AND THE WARNING LIGHTS STARTED FLASHING. AFTER SHUTTING DOWN THE CAR, AND THEN RESTARTING, THE FAULT CLEARED. EVER SINCE, THE ELECTRIC WINDOWS AND DOOR LOCKS HAVE WORKED ONLY INTERMITTENTLY. VOLVO”
— Owner report, NHTSA ODI #10453439
“MY 2006 VOLVO S40 HAS HAD NUMEROUS AND INTERMITTENT ELECTRICAL ISSUES INCLUDING GAUGES THAT GO HAYWIRE, FALSE AIRBAG FAILURE OR BRAKE FAILURE MESSAGES, LOCKS THAT DON'T ENGAGE OR DISENGAGE AND TRACTION CONTROL THAT SEEMS TO STICK OR MALFUNCTION. ON A FEW OCCASIONS THE”
— Owner report, NHTSA ODI #10369485
“WHILE DRIVING DOWN THE ROAD AT APPROXIMATELY 50 MPH I NOTICED MY DIM ( DRIVER INFORMATION MODULE) HAD COMPLETELY STOPPED WORKING. I WAS UNABLE TO READ MY SPEEDOMETER, RPM, FUEL LEVEL, AND ENGINE TEMPERATURE WHILE THE CAR WAS STILL RUNNING . AFTER RESEARCHING THIS ONLINE, IT”
— Owner report, NHTSA ODI #10817742

Read all complaints on NHTSA →

Sunroof drainage leak causing cabin flooding

ELECTRICAL SYSTEM, STRUCTURE

10 NHTSA complaints · 2012-02 → 2020-05

“WATER LEAKED INTO MY VEHICLE THROUGH THE SUNROOF, DESTROYED THE COMPUTER AND AIR AIRBAG SYSTEM. THE CARPETS ARE SOAKED WITH STANDING WATER SITTING IN THE BODY OF THE FRONT PASSENGER SIDE OF THE VEHICLE. I TOOK MY VEHICLE TO THE DEALERSHIP AND WAS TOLD THE SUNROOF DRAINAGE TUBES”
— Owner report, NHTSA ODI #10681158
“A DESIGN FLAW CAUSED FLOODING WITHIN THE CABIN OF THIS VEHICLE. THE SUNROOF DRAINAGE SYSTEM IS FAULTY AND OVER TIME LEAKS WATER INTO THE FLOOR PAN OF THE CAR, SOMETIMES ENOUGH WHERE FLOODING OCCURS. MY CAR FLOODED A FEW MONTHS BACK SO BADLY UP TO 10 GALLONS OF WATER WAS VACUUMED”
— Owner report, NHTSA ODI #10628541
“VEHICLE PASSENGER REAR FLOOR FLOODING CONTINUOUSLY. ONE DAY THE WINDSHIELD WIPERS WOULDN'T TURN OFF AND NONE OF THE INTERIOR ELECTRICAL EQUIPMENT WOULD WORK, NO POWER WINDOWS OR LOCKS. DROVE TO VOLVO, THEY STATED CLOGGED SUNROOF DRAIN AND THAT FLOORMAT HAD AFFECTED THE ECM UNDER”
— Owner report, NHTSA ODI #10672809

Read all complaints on NHTSA →

Passenger-seat airbag disable sensor fault

AIR BAGS

2 NHTSA complaints · 2007-01 → 2010-08

“2006 VOLVO S40 PASSENGER SIDE AIR BAG SENSOR IS MALFUNCTIONING. WHEN A PASSENGER IS SITTING IN THE PASSENGER SEAT, THE AIRBAG LIGHT SAYING THAT THE AIRBAG IS OFF IS OFTEN ILLUMINATED, BUT NOT ALWAYS. THE DEALER HAS TOLD ME THAT THEY HAVE ENCOUNTERED THIS PROBLEM ON SEVERAL 2006,”
— Owner report, NHTSA ODI #10351829
“TL* - THE CONTACT STATED THAT THE AIR BAG OFF LIGHT STAYED ON WHEN THEREWAS A PASSENGER IN THE SEAT. THIS HAPPENSEDINTERMITTENTLY, AND HAS BEEN HAPPENING SINCE SEPT 1, 2006. THE VEHICLE CURRENTLY HAS 9000 MILES. THE FAILURE DID NOT HAPPEN AT ANY PARTICULAR SPEED, IT NORMALLY”
— Owner report, NHTSA ODI #10177666

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)

26 crashes 1990–2024

How the 26 occupant deaths break down

21

driver deaths

5

passenger deaths

26

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2006 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.

1

complaints mentioning a crash

0

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 2006 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.