CarModelProblems.com

2004 Volvo S60 Problems & Recalls

Built from official NHTSA complaint and recall data · data through 07/14/2026

High complaint levelIts most-reported problem — Engine And Engine Cooling — runs 3.2× the fleet median for that category across the 2583 model-years tracked on this site.
198Complaints
6Recalls
12Crashes
12Fires
8Injured
0Deaths

Source: U.S. NHTSA complaint & recall data. Complaints are unverified reports from vehicle owners — a complaint is not a confirmed defect.

Is this problem acknowledged?

The most-reported problem — Engine And Engine Cooling (24.7% of complaints) — is covered by 1 NHTSA recall campaign.

Engine And Engine Cooling complaints here are 3.2× the median for that category across the 2583 model-years tracked on this site.

4 of the 6 most-reported categories on this page are backed by a recall or open investigation; the other 2 rest on owner reports alone.

Complaint categoryReportsOfficial statusReference
Engine And Engine Cooling49 · 24.7%RecalledRecall 07V226000
Fuel System, Gasoline22 · 11.1%RecalledRecall 09V483000
Engine22 · 11.1%RecalledRecall 07V226000
Electrical System19 · 9.6%No official action
Fuel/propulsion System18 · 9.1%RecalledRecall 09V483000
Vehicle Speed Control10 · 5.1%No official action

Recalled = an NHTSA safety recall covers this category, so a free repair exists. Under investigation = NHTSA has an open probe but no recall yet. Investigation closed = NHTSA examined it and closed the probe — this is not a defect finding; where a closed probe led to a recall we name the campaign. Not available = recall or investigation data could not be confirmed for this vehicle — it is not a “no”. Categories are matched by NHTSA's top-level component. Check your VIN at nhtsa.gov/recalls.

Complaints by component

ENGINE22 · 11.1%
ELECTRICAL SYSTEM19 · 9.6%
FUEL/PROPULSION SYSTEM18 · 9.1%
VEHICLE SPEED CONTROL10 · 5.1%
STEERING9 · 4.5%
ENGINE AND ENGINE COOLING:ENGINE9 · 4.5%
SEATS9 · 4.5%
AIR BAGS8 · 4%

Percentages are the share of the 198 complaints citing each component; one complaint can cite several components. “Unspecified / other” is NHTSA’s own catch-all category — we show it rather than hide it.

Recalls — 6 campaigns

Air Bags:frontal:driver Side:inflator Module

NHTSA campaign 21V766000 · 2021 · reported 09/30/2021

An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Equipment:electrical:navigational System(global Positioning System)

NHTSA campaign 10V566000 · 2010 · reported 11/08/2010

AN OVERHEATED BATTERY COULD LEAD TO A FIRE. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Fuel System, Gasoline:delivery:fuel Pump

NHTSA campaign 09V483000 · 2009 · reported 12/18/2009

IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Service Brakes, Hydraulic:foundation Components:master Cylinder

NHTSA campaign 07E023000 · 2007 · reported 03/29/2007

LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Engine And Engine Cooling

NHTSA campaign 07V226000 · 2007 · reported 06/05/2007

MISFIRE MAY OCCUR DURING DRIVING THAT, IN TURN, WILL REDUCE THE ENGINE TORQUE AND IN THE WORST CASE SCENARIO, THE ENGINE MAY STALL WITHOUT WARNING. IN CERTAIN TRAFFIC SITUATIONS THIS COULD CAUSE AN UNSAFE SITUATION AND POSSIBLY A CRASH. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Steering:linkages

NHTSA campaign 04V029000 · 2004 · reported 01/16/2004

THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH. Recall repairs are free at authorized dealers.

PARK-IT: NO  · PARK-OUTSIDE: NO  ·  OVER-THE-AIR FIX: NO

Park it Park outside Specimen badges — shown on a recall card only when NHTSA sets the flag. None of the campaigns above carries either flag. Always check your own vehicle by VIN at nhtsa.gov/recalls.

What owners report

“THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THE DRIVERS SPEED WAS 25 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING. THE CHECK ENGINE…”NHTSA complaint 10453769 — filed 04/02/2012 · ENGINE AND ENGINE COOLING
“THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE VEHICLE DECELERATED WITHOUT WARNING AND STALLED. THE CONTACT WAS…”NHTSA complaint 10450359 — filed 03/05/2012 · ENGINE AND ENGINE COOLING
“AT ANY GIVEN TIME THE VEHICLE STALLS. I LOOSE ALL POWER AND HAVE TO RESTART THE CAR. I'VE TAKEN THE CAR TO THE DEALER THEY…”NHTSA complaint 10430398 — filed 10/16/2011 · ENGINE AND ENGINE COOLING

Excerpts are shortened and scrubbed of personal details; they are individual, unverified reports.

Complaint trend by year filed

3320081842201030242012191720141462016922018452021132024

Frequently asked questions

What are the most common problems with the 2004 Volvo S60?

Engine and engine cooling issues are the most-reported category, cited in 49 of 198 NHTSA complaints (24.7%), followed by fuel system, gasoline (22), engine (22), electrical system (19). Complaints are unverified owner reports.

How many complaints does the 2004 Volvo S60 have?

198 complaints were on file with NHTSA as of 07/14/2026. Of those, 12 involved a crash, 12 involved a fire, and 8 reported injuries. No deaths were reported.

Does the 2004 Volvo S60 have any recalls?

Yes — 6 NHTSA safety recall campaigns, including campaign 21V766000. Recall repairs are free at authorized dealers. Check your specific vehicle by VIN at nhtsa.gov/recalls.

Has NHTSA acted on the 2004 Volvo S60's reported problems?

4 of the 6 most-reported complaint categories on this page are backed by an NHTSA safety recall or open investigation; the rest are unverified owner reports. A recall means a free repair is available at authorized dealers.

Is a complaint proof of a defect?

No. Complaints are reports submitted by consumers to NHTSA. NHTSA does not verify individual complaints, and a complaint is not proof that a defect exists.

About this data — Complaint figures on this page are consumer reports submitted to the National Highway Traffic Safety Administration (NHTSA), a U.S. government agency. NHTSA does not verify individual complaints; a complaint is not proof that a defect exists, and counts reflect what owners chose to report, not confirmed failure rates. Recall information comes from official NHTSA safety recall campaigns; recall repairs are free at authorized dealers. Always check your specific vehicle by VIN at nhtsa.gov/recalls. CarModelProblems.com is an independent site and is not affiliated with NHTSA or any vehicle manufacturer. Data through 07/14/2026.