Is the 2004 Volvo S60 a bad year?
198 owner complaints to NHTSA. Engine complaints: 83, 8.3× a quiet S60 year.
Keep it, but watch the engine
Half of the engine complaints for this year were filed at 68k–103k miles, where you are now.
The verdict moves with mileage: the same car reads differently at 30,000 and at 150,000 miles.
What 2004 S60 owners report, by mileage
Each system owners named in five or more complaints, with the mileage range where the middle half of those complaints were filed. Read at 83,000 miles.
| SYSTEM | COMPLAINTS | MIDDLE HALF FILED AT | TYPICAL US REPAIR BILLS |
|---|---|---|---|
| EngineSTANDS OUT | 80 (40%) | 70k–103k miles · around this mileage | Valve cover gasket replacement $110–$500 · Timing chain replacement $1,000–$4,000 |
| Fuel systemSTANDS OUT | 55 (28%) | 62k–116k miles · around this mileage | Fuel pump replacement $220–$1,500 · Fuel injector replacement (one injector) $300–$1,200 |
| Electrical system | 21 (11%) | 67k–140k miles · around this mileage | 12-volt battery replacement $100–$400 · Starter motor replacement $350–$1,200 |
| Speed control | 11 (6%) | 27k–95k miles · around this mileage | — |
| Seats | 12 (6%) | too few with a mileage | — |
| Transmission and drivetrain | 12 (6%) | too few with a mileage | — |
| Air bags | 9 (5%) | too few with a mileage | — |
| Steering | 9 (5%) | too few with a mileage | — |
| Tires | 9 (5%) | too few with a mileage | — |
| Brakes | 8 (4%) | too few with a mileage | — |
| Exterior lighting | 7 (4%) | too few with a mileage | — |
| Equipment | 5 (3%) | too few with a mileage | — |
Bills are typical US ranges from the sources named in the tool (J.D. Power, Kelley Blue Book, CarParts.com and others), printed only for systems that stand out or sit at or ahead of 83,000 miles. Not a quote.
What owners reported alongside their complaints
Of 198 complaints: 12 mention a crash · 12 mention a fire · 8 report an injury · 2 say the car was towed.
No complaints in the last 12 months; the newest was filed in Jul 2024.
Counts of what owners wrote in their complaints, not verified by anyone.
In owners' own words
2004 S60 Volvo stalls while driving. Most recent occurrence stalled while turning, forcing the driver to drive off the road to avoid traffic.
2004 Volvo S60 2.5T. Purchased the car used in sept 07. 6-5-08 panel displayed open rear door while driving 65MPH on highway, my door was not opened.
1. Vehicle stalled 2 times, last year and on 08/09/2010 while driving on highway. I was able to restart both time.
Unedited excerpts from complaints filed with NHTSA, chosen by mileage (nearest 83,000 miles), not by content. Unverified.
Recalls for the 2004 Volvo S60: 6
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. An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
The batteries on those units may overheat. An overheated battery could lead to a fire.
When exposed to certain environmental conditions (Hot climate and temperature cycling) over time and in combination with varying fuel quality, the fuel pump can develop cracks in the fuel pump flange. 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.
On certain passenger vehicles, the fuel pressure sensor located on the left end of the fuel rail may, at times, transmit incorrect signal regarding the fuel pressure to the engine control module. 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.
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. Loss of brake fluid can result in poor braking performance, possibly resulting in a vehicle crash.
On certain passenger vehicles, the front control arms may not have been manufactured correctly and, as a result, the stud and nut that secure the arm to the spindle may lose their initial axial tension. This driving condition could eventually lead to separation between the front control arm and the spindle, which could result in a crash.
A recall may cover only some cars of a model year; the campaign size counts every model and year it lists. Enter your VIN at nhtsa.gov/recalls: dealers fix open recalls free.
Service bulletins from Volvo: 110
Repair instructions Volvo sent its dealers for symptoms seen in the shop on the 2004 Volvo S60. Ask a dealer or mechanic for a bulletin by its number.
The 5 speed automatic transmission, AW55-50/51, has a bolt on top that anchors the B4 band, which applies 3rd gear
Retailers should only use a Volvo part number on claims for items purchased directly from Volvo
The Volvo Certified Pre-Owned (VCPO) warranty on all vehicles certified and retailed on or after 1/1/05…
VIDA will not support Windows 8.1 after June 30th 2017
Neighbouring years
2003 S60: 120 complaints, keep it · 2005 S60: 44 complaints, keep it.
Every Volvo S60 year
2000 · 2001 · 2002 · 2003 · 2004 · 2005 · 2006 · 2007 · 2008 · 2009 · 2011 · 2012 · 2013 · 2014 · 2015 · 2016 · 2017 · 2018 · 2019 · 2020 · 2021 · 2022 · 2023 · 2024 · All S60 years side by side
Other Volvo models: Volvo C70 · Volvo S40 · Volvo S70 · Volvo S80 · Volvo V70 · Volvo V70XC · Volvo XC40 · Volvo XC60 · Volvo XC70 · Volvo XC90. All makes and models.
Questions
Is the 2004 Volvo S60 a bad year?
198 owner complaints to NHTSA. Engine complaints: 83, 8.3× a quiet S60 year. At 83,000 miles the tool says: Keep it, but watch the engine. Half of the engine complaints for this year were filed at 68k–103k miles, where you are now.
What are the most common problems with the 2004 Volvo S60?
By owner complaints to NHTSA: engine (80), fuel system (55), electrical system (21), speed control (11), seats (12). Half of the engine complaints were filed between 68k–103k miles.
How many recalls does the 2004 Volvo S60 have?
6 recall campaigns list this model year: Air bags (NHTSA 21V-766), Equipment (NHTSA 10V-566), Fuel system (NHTSA 09V-483), Engine (NHTSA 07V-226) and more. A recall may cover only some cars; check by VIN at nhtsa.gov/recalls.
Method: counts of unverified owner complaints filed with NHTSA, compared only with other years of the same model (sales volumes are unknown, so no failure rate is computed). A system stands out at 40+ complaints and at least twice the model's quiet (lower-quartile) year, or twice the share across every vehicle of that model year. The mileage range is the 25th to 75th percentile of the mileages owners reported. Data received by NHTSA through November 5, 2026. Repair prices are typical US ranges from named sources, not quotes. Not a diagnosis and not financial advice. PulsCar is not affiliated with NHTSA. Check this car at your own mileage.