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#BS-2004-VOLS40-6DA5

2004 Volvo S40

Based on reports from 75 owners and 6 recalls for this exact model.

Complaints

Crashes

Fires

Recalls

TSBs

237

🟡

Preliminary Verdict

Think Twice

Based on 75 complaints, 7 crashes, 2 fires, and 6 recalls.

See full verdict with buy/skip conditions

Preview: What's in your full report

Each card shows a real sample from your report — unlock all 10 sections from $1.20

Mechanic Inspection Checklist

!Check the ElectricalHIGH

9 owners reported electrical issues — failures commonly reported around 53K miles.

!Inspect the BrakesMED

Look for symptoms of wear and premature failure

+ 6 more items in full checklistUnlock

Failure Timeline by Mileage

0–30K

30–60K

60–90K

90–120K

120–150K

150K+

Peak failure range: 0–30K miles (16 reports) • Median: 53K miles

Full report: which components fail at each mileageUnlock

30,000-Mile Cost Projection

Best Case

$X,XXX

Most Likely

$X,XXX

Worst Case

$X,XXX

Top cost driver: Electrical (9 reports).

Includes fuel costs, common repairs, and recall riskUnlock

Also in your report

Owner Intelligence

AI-synthesized themes from real complaints

Buyer Lot Checklist

Questions, test drive checks, walk-away triggers

Negotiation Talking Points

Data-backed dollar deductions

Buy / Skip Verdict

Final recommendation with conditions

10 sections total in the full reportUnlock all

Where the complaints fall

Electrical9 (12%)

Brakes7 (9%)

Airbags6 (8%)

Fuel System5 (7%)

Engine4 (5%)

Air Bags:frontal3 (4%)

Speed Control3 (4%)

Steering3 (4%)

2004 Volvo S40: Known Issues & Problem Areas

Electrical Issues

Electrical complaints account for 12% of all reports filed for the 2004 Volvo S40, with 9 owners filing complaints with NHTSA. The median mileage at time of complaint is 52,500 miles, suggesting issues tend to surface around the 53K-mile mark.

Brakes Issues

Brakes complaints account for 9% of all reports filed for the 2004 Volvo S40, with 7 owners filing complaints with NHTSA. Owners should pay attention to brakes-related symptoms during test drives and pre-purchase inspections.

Airbags Issues

Airbags complaints account for 8% of all reports filed for the 2004 Volvo S40, with 6 owners filing complaints with NHTSA. Owners should pay attention to airbags-related symptoms during test drives and pre-purchase inspections.

Fuel System Issues

Fuel System complaints account for 7% of all reports filed for the 2004 Volvo S40, with 5 owners filing complaints with NHTSA. Owners should pay attention to fuel system-related symptoms during test drives and pre-purchase inspections.

Data sourced from NHTSA owner complaints and community reports. The full report analyzes severity, repair costs, and failure patterns for each category.

Complaint trend by year

Complaints filed with NHTSA by year for the 2004 Volvo S40. Recent trend: increasing.

Don't negotiate blind — know what this car costs to own

Repair costs • Negotiation scripts • Mechanic checklist • Buy/skip verdict

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Recall History (6 recalls)

03V284000Dec 2003

EQUIPMENT:OTHER:LABELS

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.

03V424000Jan 2004

FUEL SYSTEM, GASOLINE

ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.

04V493000Nov 2004

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM:HOSES, LINES/PIPING, AND FITTINGS

ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.

06V137000Jun 2006

FUEL SYSTEM, GASOLINE

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.

08V033000Feb 2008

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

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.

+ 1 more recall in the full report

Recall severity analysis & seller scripts

The full report rates each recall's severity and gives you scripts for asking the seller about recall completion.

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The worst model year for the Volvo S40 is the 2007 — worth knowing if you're cross-shopping years. The biggest problem area is engine.

2004 Volvo S40 vs. Class Average (Compact Cars)

This vehicle

Class avg

205

Below the class average — fewer complaints than typical compact cars vehicles. A good sign.

Complaint counts correlate with sales volume — popular vehicles naturally generate more reports. The full report normalizes for this.

About this data

NHTSA Complaints

Federal database of owner-filed safety complaints. 75 records for this vehicle.

NHTSA Recalls

Manufacturer-issued safety recalls. 6 recalls found for this vehicle.

Repair Cost Data

Real-world repair costs from owner reports and independent databases.

Other Volvo S40 Model Years

2011 2010 2009 2008 2007 2006 2005 2004 2003 2002 2001 2000 1999

View all Volvo S40 years →

2004 Volvo S40: Frequently Asked Questions

What is the most common problem with the 2004 Volvo S40?

The most commonly reported issue with the 2004 Volvo S40 is related to the electrical, with 9 complaints filed with NHTSA.

Is the 2004 Volvo S40 reliable?

The 2004 Volvo S40 has 75 complaints, 7 crash reports, and 2 fire reports filed with NHTSA. This is below the class average — a positive sign for reliability.

How much does it cost to fix 2004 Volvo S40 problems?

Repair costs vary by issue. The full BumperScan report includes detailed repair cost estimates (low/median/high) for every major issue, plus a 30,000-mile total cost of ownership projection.

Does the 2004 Volvo S40 have any recalls?

Yes, the 2004 Volvo S40 has 6 recalls on record. The full report includes recall severity analysis and scripts for asking the seller about recall completion.

What mileage do Volvo S40 problems start?

Based on 47 complaints with mileage data, the median mileage at time of complaint is 52,500 miles. The highest concentration of reported issues occurs in the 0–30K mile range. The full report breaks down exactly which components fail at each mileage bracket.

What’s in the full report?

10 sections of AI analysis: severity-ranked issues, component scores (0-100), 30K-mile cost projection, failure timeline by mileage, recall details with seller scripts, owner sentiment analysis, mechanic checklist, buyer lot checklist, negotiation ammo with dollar figures, and a buy/skip verdict.

How is this different from free NHTSA data?

NHTSA gives you raw complaint text. BumperScan cross-references 2.1M+ complaints with community repair cost data, EPA fuel data, and recall records — then uses AI to synthesize it into actionable advice with dollar figures.

How is this different from Carfax?

Carfax is VIN-specific history ($45/report). BumperScan is model-level reliability intelligence — what problems this car is known for, what they cost, and whether you should buy it. Complementary, not competing.

What if the report isn’t useful?

100% money-back guarantee. If the report doesn’t help you make a more informed decision, we’ll refund you — no questions asked.