2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2004 · All trims · All engines
Choose the year and equipment for your written issues and visual request.
Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy
Visual coming soon
Your interest helps us choose what to build next.
Visual Known Issues · Coming soon
$4.99/month plus taxes at launch · No payment today
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Volvo S60 has 10 documented known issues, with 5 rated critical. The most serious are 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, 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). Across all issues with published estimates, repair costs range from $150 to $4,500. DIY maintenance guides at au7o.io.
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
SEATS
VOLVO IS RECALLING CERTAIN PASSENGER VEHICLES EQUIPPED WITH POWER FRONT PASSENGER SEATS. THE FRONT SEAT RAIL'S DETECTION SYSTEM WAS MANUFACTURED INCORRECTLY AND MAY PERMIT THE PASSENGER TO FORWARD THE SEAT BEYOND THE INTENDED MAXIMUM.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER
CERTAIN CARDONE MASTER CYLINDERS WITH PART NUMBERS 10-2925, 10-2987, 10-2987MZA, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, AND 11-3156, AND WITH DATE CODES LOWER THAN DCA7078 SOLD AS REPLACEMENT EQUIPMENT FOR USE ON THE VEHICLES LISTED ABOVE. THE SEAL ON MASTER CYLINDER CAN FAIL AND LEAK BRAKE FLUID.
EQUIPMENT:OTHER:LABELS
CERTAIN VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, "TIRE SELECTION AND RIMS." THE LABEL DENOTING THE TIRE AND LOADING PRESSURE INFORMATION IS INCORRECT.
Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Volvo S60 has 10 documented issues. The most frequently reported are: Rear Shock Tower and Trunk Floor Corrosion, Recall 04V029000: Front Control Arm Stud and Nut Can Lose Tension, Risking Separation from the Spindle, Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000). Of these, 5 are rated critical and should be addressed promptly.
The 2004 Volvo S60 has 10 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 5 issues are rated critical: 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 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 $150 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Rear Shock Tower and Trunk Floor Corrosion, typically costs $500-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
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.
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 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.
The upper engine torque mount on P2-platform S60 models is a common wear item that fails between 60,000-100,000 miles. The hydraulic-filled mount splits and leaks fluid, causing excessive engine movement during acceleration and deceleration. This leads to harsh shifting feel, dri… Repairs typically run $150-$400. 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.
