Volvo · Known Issues
2001-2025 Volvo S60 Problems: 24 Known Issues
2001-2025 model years · 1,770+ owner reports · Updated September 2026
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2001-2025 model years · 1,770+ owner reports · Updated September 2026
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According to Au7o's analysis of 1,770+ owner reports, the 2001-2025 Volvo S60 has 24 documented known issues, with 13 rated critical. The most serious are Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000), Recall 04V451000: Electric Cooling Fan Overheating and Engine-Bay Fire Risk (2001 S60), ABS, ESC and Traction Control Loss From BCM2 Diagnostic Fault (Recall 23V012000), Rear Shock Tower and Trunk Floor Corrosion ($500-$2,500 repair), Recall 04V029000: Front Control Arm Stud and Nut Can Lose Tension, Risking Separation from the Spindle, Recall 25V179000 — S60 Plug-In Hybrid Battery Module Short Circuit (Do Not Charge), S60 Seat Belt Retractor Fails to Hold a Child Restraint — FMVSS 208 Recall 21V682000, S60 Seat Belt Anchor Cable Fatigue — Safety Recall 20V378000, 2019-2020 S60 Automatic Emergency Braking Recall — ASDM Software Update (R29998), "No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction ($250-$2,500 repair), Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000), Electronic Throttle Module (ETM) Failure ($300-$700 repair) and AW55-50SN 5-Speed Automatic Transmission and TCM Failure ($900-$4,500 repair). The most commonly reported issue is T5/T6 PCV Oil Trap System Failure and Oil Consumption with 780 owner reports. Across all issues with published estimates, repair costs range from $150 to $4,500. DIY maintenance guides at au7o.io.
AIR BAGS:FRONTAL
Volvo Car USA, LLC. (Volvo Car) is recalling certain 2019-2024 S60 vehicles. The passenger air bag may not be secured properly, which can cause the air bag to deploy improperly.
BACK OVER PREVENTION:SOFTWARE
Volvo Car USA, LLC (Volvo Car) is recalling certain 2021-2025 XC40, 2022 V90, 2022-2025 S90, V90CC, C40, XC60, 2023-2025 S60, V60, V60CC, XC90, and 2025 EC40 and EX40 vehicles. The rearview camera image may not display when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
BACK OVER PREVENTION:SOFTWARE
Volvo Car USA, LLC (Volvo Car) is recalling certain 2021-2025 XC40, 2022 V90, 2022-2024 C40BEV, 2022-2025 S90, V90CC, XC60, 2023-2025 S60, V60, V60CC, XC90, and 2025 EC40, and EX40 vehicles. The rearview camera image may not display when the vehicle is placed in reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 111, "Rear Visibility."
ENGINE AND ENGINE COOLING:ENGINE:ENGINE CONTROL MODULE (ECU/ECM)
Volvo Car USA, LLC (Volvo Car) is recalling certain 2022-2023 S60, V60, S90L, XC60, and XC90 vehicles. An electronic control module (ECM) software error may prevent the combustion engine from starting, causing a loss of drive power.
SERVICE BRAKES, HYDRAULIC
Volvo Car USA, LLC (Volvo Car) is recalling certain 2023 S60, V60, V60CC, V90CC, XC60, XC90, XC40, and C40 vehicles. A diagnostic error in the Brake Control Module 2 (BCM2) may cause a loss of Antilock Brake System (ABS), Electronic Stability Control (ESC), and traction control.
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According to Au7o's analysis of 1,770+ owner reports, the 2001-2025 Volvo S60 has 24 documented issues. The most frequently reported are: Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000), Recall 04V451000: Electric Cooling Fan Overheating and Engine-Bay Fire Risk (2001 S60), ABS, ESC and Traction Control Loss From BCM2 Diagnostic Fault (Recall 23V012000). Of these, 13 are rated critical and should be addressed promptly.
The 2001-2025 Volvo S60 has 24 known issues documented across 1,770+ owner reports. 13 issues are rated critical: Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000) and Recall 04V451000: Electric Cooling Fan Overheating and Engine-Bay Fire Risk (2001 S60) and ABS, ESC and Traction Control Loss From BCM2 Diagnostic Fault (Recall 23V012000) and Rear Shock Tower and Trunk Floor Corrosion and Recall 04V029000: Front Control Arm Stud and Nut Can Lose Tension, Risking Separation from the Spindle and Recall 25V179000 — S60 Plug-In Hybrid Battery Module Short Circuit (Do Not Charge) and S60 Seat Belt Retractor Fails to Hold a Child Restraint — FMVSS 208 Recall 21V682000 and S60 Seat Belt Anchor Cable Fatigue — Safety Recall 20V378000 and 2019-2020 S60 Automatic Emergency Braking Recall — ASDM Software Update (R29998) and "No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction and Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000) and Electronic Throttle Module (ETM) Failure and AW55-50SN 5-Speed Automatic Transmission and TCM Failure. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Volvo S60 issues range from $0 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Reliability varies across model years of the Volvo S60. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2001-2025 Volvo S60 with 24 documented issues documented across 1,770+ owner reports.
Volvo Car USA recalled 2019-2020 S60 sedans among several other models because the car's low-pressure fuel pump can blow a fuse and fail. When that happens the engine can stall. NHTSA's consequence statement is direct: a stall increases the risk of a crash, which is why this was… Severity: high.
Volvo recalled the 2001 S60 under NHTSA campaign 04V451000 because, under certain operating conditions, some electric engine cooling fans can overheat. The overheating fan can cause heat damage in the engine compartment and, in rare instances, start a fire there. The recall recor… Severity: high.
If you own a 2023 Volvo S60, this recall applies to the sedan's brake electronics rather than to any mechanical brake part. A diagnostic error in the Brake Control Module 2 (BCM2) can result in the loss of the Antilock Brake System, Electronic Stability Control and traction contr… Severity: high.
First-generation S60 models are prone to severe rust in the rear shock tower mounting points and trunk floor, particularly in salt-belt regions. Water intrusion through deteriorated trunk seals and blocked drain holes accelerates the corrosion. In advanced cases, the shock tower… Repairs typically run $500-$2,500. Severity: high.
Volvo recalled certain 2004 S60 sedans because the front control arms may not have been manufactured correctly. As a result, the stud and nut that secure the control arm to the spindle can lose their initial axial tension. Under certain driving conditions an S60 owner may notice… Severity: high.
If you own a 2020-2022 S60 Recharge plug-in hybrid, this recall applies to your car's high-voltage battery. Volvo reported that a short circuit can occur inside a battery module when the pack is at full charge and the S60 is parked. NHTSA classified the defect under Electrical Sy… Severity: high.
Recall 21V682000 covers 2021 and 2022 Volvo S60 sedans whose front seat belt automatic locking retractors may deactivate early. This is a compliance recall: Volvo reported the vehicles fail to meet Federal Motor Vehicle Safety Standard 208, "Occupant Crash Protection." The practi… Severity: high.
S60 sedans from 2011 through 2018 are covered by Volvo recall 20V378000. The problem is the flexible steel cable that connects the seat belt to each front outboard seating position: Volvo reported that this cable may fatigue over time. If the cable has fatigued, the seat belt may… Severity: high.
Volvo Cars USA recalled 2019-2020 S60 sedans as part of NHTSA campaign 20V144000. The cause given is a software/hardware incompatibility that can leave the Automatic Emergency Brake (AEB) system unable to detect obstacles and engage as intended. For an S60 owner, the practical me… Severity: high.
P3-generation S60 owners report a sudden 'No Oil Pressure - Stop Safely' message on the driver information display, often with no prior noise or warning, and frequently while the engine still has oil on the dipstick. CarComplaints lists this as the number-one engine complaint on… Repairs typically run $250-$2,500. Severity: high.
Volvo recalled 2001-2004 S60 sedans sold or registered in hot-climate states as part of NHTSA campaign 09V483000. On affected cars, long-term exposure to hot climate and repeated temperature cycling, combined with varying fuel quality, can cause the fuel pump flange to develop cr… Severity: high.
The 2001-2004 S60 (and other P2 platform Volvos) is notorious for ETM failure due to a design flaw in the throttle body electronics. The module develops internal solder joint cracks and corroded contacts, causing the car to enter limp mode, stall at idle, or refuse to accelerate. Repairs typically run $300-$700. Severity: high.
P2-generation S60s use the Aisin-Warner AW55-50SN 5-speed automatic. Two related failures dominate owner reports: the transmission control module (TCM), which is mounted inside the transmission case and bathed in hot ATF, develops cracked solder joints and internal failures, and… Repairs typically run $900-$4,500. Severity: high.
The positive crankcase ventilation (PCV) system oil trap on the S60 T5 and T6 engines fails prematurely, causing excessive crankcase pressure, oil leaks, and increased oil consumption. The oil trap membrane hardens and cracks, allowing oil mist to enter the intake manifold and be… Repairs typically run $400-$1,200. Severity: medium.
The T6 twin-charged (supercharger + turbocharger) engine in the S60 has two common issues: the supercharger drive belt wears prematurely and the turbocharger oil feed line develops leaks. The supercharger belt drives the Roots-type supercharger for low-RPM boost and begins squeal… Repairs typically run $200-$2,500. Severity: medium.
The plastic thermostat housing on P2-platform S60 turbo models (T5 and 2.4T) is prone to cracking and leaking coolant, especially as the housing ages and becomes brittle from heat cycling. The leak typically starts as a slow seep around the housing gasket or where the housing mee… Repairs typically run $200-$500. Severity: medium.
The Volvo S60 P2 platform has the Rear Electronic Module (REM) located in the trunk area where it is susceptible to water intrusion from trunk seal leaks or condensation. Water damage causes intermittent electrical failures in rear lighting, fuel pump, and other circuits. Repairs typically run $200-$800. Severity: medium.
The P2 S60's instrument cluster is a self-contained module (DIM) that sits on the CAN bus. Thermal cycling in the dash cracks the solder joints where the cluster's connector pins and internal components attach to the circuit board. The result is intermittent, then permanent, clus… Repairs typically run $250-$900. Severity: medium.
Fuel system complaints are the single largest NHTSA category on the early P2 S60 (roughly 74 complaints on the 2002 and 92 on the 2001). Two distinct parts fail. The fuel level sender's resistive card wears where the wiper arm sweeps, so the gauge reads erratically, sticks full,… Repairs typically run $350-$1,100. Severity: medium.
Volvo Car USA is recalling certain 2023-2025 S60 sedans because the rearview camera image may not appear on the center display when the car is shifted into reverse. Because the image can be missing at the moment it is needed, these S60s do not meet Federal Motor Vehicle Safety St… Severity: medium.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.