2004 Volvo S40: problems, recalls and reliability
6 recalls and 48 owner complaints on record; the weakest area is air bags (17% of complaints); the 2002 and 2003 model years look more trouble-free.
Data updated weekly · latest recall Nov 2010
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 48 owner complaints filed with NHTSA for this exact model year.
“Having a coolant leakage, crash mode and safety alarm system check keeps coming on...when crash mode comes on...car just shuts off.”Owner report · Forward Collision Avoidance · Nov 2020
“Tl* the contact owns a 2004 volvo s40 equipped with cooper zeon rs3-a tires, size: 205/55/16r (na). The contact heard a loud humming noise coming from the tires. The inside of the tread had a line and the contact noticed damage or an opening. An independent mechanic confirmed that the tires were separating at the tread line. An unknown tire dealer stated that the tires were not under warranty after the tires had been owned for over three years. The manufacturer was notified. The vehicle failure mileage was 145,000. The tire failure mileage and VIN were unknown.”Owner report · Tires · Sep 2018
“No collision. Srs light has been coming on since 2007. Dealership has replaced wiring, air bags and nothing helps. Srs light comes on every 7 to 12 months. This has been going on for 11 years.”Owner report · Air Bags · May 2018
Show 7 more owner reports
“Brake pedal is too close to accelerator pedal. Whenever I operate the gas pedal, the side of my shoe also activates the brake. The problem is aggravated by the center tunnel carpet intruding on the minimal accelerator pedal space.”Owner report · Service Brakes · Sep 2016
“Tl* the contact owns a 2004 volvo s40. The contact stated that the accelerator pedal and the brake pedal became difficult to depress. Also, the contact mentioned that due to the proximity of the pedals, the brake pedal was inadvertently depressed when applying the accelerator pedal. The vehicle was not diagnosed. The manufacturer was notified of the failure. The failure mileage was not available.”Owner report · Vehicle Speed Control · Jan 2015
“Tl* the contact owns a 2004 volvo s40. While driving at approximately 10 mph, the vehicle stalled without warning. The vehicle did not restart. The vehicle was taken to a dealer where it was diagnosed that the pem was faulty. The vehicle was repaired. The manufacturer was made aware of the issue. The failure mileage was 100,625. Updated 04/07/15*lj updated 11/3/2015*js”Owner report · Engine · Dec 2014
“I just brought the car from jcl auto sales in allentown pa at the end of august and my check engine continues to come on. *tr”Owner report · Engine · Nov 2014
“For the past two mornings my car has no brakes when I first start my car, once I have been driving for a few minutes it's okay, but first thing the past two mornings I haven't had brakes! *tr”Owner report · Service Brakes · Oct 2014
“Tl* the contact owns a 2004 volvo s40. The contact stated that the air bag warning light illuminated without warning. The dealer was contacted and advised him that the occupant weight sensor may have failed and needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and they offered him a 10 percent coupon. The failure mileage was approximately 95,000. The current mileage was approximately 110,000.”Owner report · Air Bags · Oct 2012
“Tl* the contact owns a 2004 volvo s40. The contact stated the floor behind the drivers side seat was soaking wet. The dealer was contacted and advised him that the water was entering the vehicle from the drainage on the sunroof. The manufacturer was contacted and offered no assistance. The vehicle was not repaired. The failure and current mileage was approximately 97,000. The VIN was unavailable.”Owner report · Structure · Sep 2011
When filing, owners marked a crash in 5 of these complaints and injuries in 4 - self-reported to NHTSA, not verified accident statistics.
Recalls - 6 campaigns
ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.
Remedy: DEALERS WILL INSPECT, AND IF NECESSARY, REPLACE THE VACUUM HOSE. THE RECALL BEGAN ON NOVEMBER 29, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.
Remedy: DEALERS WILL INSTALL A V-CLAMP TO THE FUEL RAIL. OWNER NOTIFICATION BEGAN ON JANUARY 28, 2004. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
ON CERTAIN VEHICLES SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA, REOCCURRING, LONG-TERM EXPOSURE TO CERTAIN ENVIRONMENTAL CONDITIONS SUCH AS SALTY-WET CONDITIONS, IT IS POSSIBLE FOR THE PUMP ELECTRONIC MODULE (PEM) TO BECOME CORRODED INTERNALLY. THIS CAN CAUSE A FAULTY SIGNAL TO THE FUEL PUMP, RESULTING IN LOW OR NO FUEL PRESSURE TO THE ENGINE.
Remedy: DEALERS WILL REPLACE THE PEM AND INSTALL IT IN A NEW LOCATION TO PREVENT CORROSION. THE RECALL BEGAN ON FEBRUARY 20, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE SECOND ISOFIX GUIDE WAS NOT INSTALLED IN THESE VEHICLES AND, IN CERTAIN CASES, THE OWNER'S MANUAL ISOFIX INFORMATION IS INCORRECT.
Remedy: OWNERS WILL RECEIVE A LETTER/PACKAGE CONSISTING OF THE SECOND ISOFIX GUIDE WITH INSTALLATION INSTRUCTIONS, AND IN CERTAIN CASES, THE CORRECTED OWNER'S MANUAL MAY BE PROVIDED. IF THE OWNER WANTS TO TAKE THEIR VEHICLE TO A VOLVO DEALER FOR INSTALLATION OF THE GUIDE, IT WILL BE PERFORMED AT NO CHARGE TO THE OWNER. OWNER NOTIFICATION BEGAN ON DECEMBER 19, 2003. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH T5 TURBO ENGINES, THE POLYAMIDE TUBE IN THE FUEL LINE IS SENSITIVE TO THE EXTREME TEMPERATURES THAT MAY OCCUR IN THE AREA WHERE THE TURBO/EXHAUST MANIFOLD IS LOCATED.
Remedy: DEALERS WILL CHANGE THE FUEL LINE MATERIAL TO TEFLON FREE OF CHARGE. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.
Specifications
Factory options offered for the 2004 model year, decoded from the NHTSA vPIC database. Individual vehicles have one of each.
How other years compare
Check your exact S40 by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2004 Volvo S40 reliable?
NHTSA has 48 owner complaints and 6 recall campaigns on record for the 2004 Volvo S40. The most complained-about area is air bags (17% of complaints).
At what mileage do 2004 Volvo S40 problems usually appear?
Half of the complaints that mention mileage were filed at 64,500 miles or less.
Does the 2004 Volvo S40 have open recalls?
6 recall campaigns have been issued, the latest concerning service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.