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#BS-2004-VOLS60-710F2004 Volvo S60
Based on reports from 262 owners and 6 recalls for this exact model.
Preliminary Verdict
Red Flag
Based on 262 complaints, 22 crashes, 15 fires, and 6 recalls.
Top reported problems
noise from exhaust
1 complaints • Severity 8/10
fuel gauge faulty
1 complaints • Severity 8/10
chasis system fails
1 complaints • Severity 10/10
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Mechanic Inspection Checklist
71 owners reported engine issues — failures commonly reported around 81K miles.
Failure Timeline by Mileage
Peak failure range: 90–120K miles (66 reports) • Median: 81K miles
30,000-Mile Cost Projection
Best Case
Most Likely
Worst Case
Top cost driver: Engine (71 reports).
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
Where the complaints fall
2004 Volvo S60: Known Issues & Problem Areas
Engine Issues
Engine complaints account for 27% of all reports filed for the 2004 Volvo S60, with 71 owners filing complaints with NHTSA. The median mileage at time of complaint is 80,550 miles, suggesting issues tend to surface around the 81K-mile mark.
Fuel System Issues
Fuel System complaints account for 18% of all reports filed for the 2004 Volvo S60, with 47 owners filing complaints with NHTSA. Owners should pay attention to fuel system-related symptoms during test drives and pre-purchase inspections.
Electrical Issues
Electrical complaints account for 7% of all reports filed for the 2004 Volvo S60, with 19 owners filing complaints with NHTSA. Owners should pay attention to electrical-related symptoms during test drives and pre-purchase inspections.
Speed Control Issues
Speed Control complaints account for 4% of all reports filed for the 2004 Volvo S60, with 10 owners filing complaints with NHTSA. Owners should pay attention to speed control-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 S60. Recent trend: increasing.
Don't negotiate blind — know what this car costs to own
Repair costs • Negotiation scripts • Mechanic checklist • Buy/skip verdict
Recall History (6 recalls)
STEERING:LINKAGES
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. UNDER CERTAIN DRIVING CONDITIONS, THE STEERING MAY BECOME LESS RESPONSIVE AND THE DRIVER MAY EXPERIENCE STEERING WHEEL PLAY.
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.
ENGINE AND ENGINE COOLING
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. IF THE SIGNAL IS OUTSIDE OF THE PRE-PROGRAMMED ALLOWABLE LIMITS, A DIAGNOSTIC TROUBLE CODE MAY BE SET AND THE CHECK ENGINE LIGHT WILL COME ON. THE SOLDERED JOINTS ON THE CIRCUIT BOARD OF THE FUEL PRESSURE SENSOR MAY CRACK DUE TO TEMPERATURE CHANGES AND EXCESSIVE VIBRATIONS.
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
VOLVO IS RECALLING CERTAIN MODEL YEAR 2001-2005 S80, MODEL YEAR 2001-2004 V70, S60, XC70 AND MODEL YEAR 2003-2005 XC90 VEHICLES SOLD IN OR REGISTERED IN THE STATES OF ALABAMA, ARIZONA, ARKANSAS, CALIFORNIA, FLORIDA, GEORGIA, HAWAII, KENTUCKY, LOUISIANA, MISSISSIPPI, NEVADA, NEW MEXICO, NORTH CAROLINA, OKLAHOMA, SOUTH CAROLINA, TENNESSEE, TEXAS, UTAH, VIRGINIA AND THE U.S. TERRITORIES. 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.
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.
+ 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.
The worst model year for the Volvo S60 is the 2012 — worth knowing if you're cross-shopping years. The biggest problem area is engine.
2004 Volvo S60 vs. Class Average (Compact Cars)
This vehicle
262
Class avg
205
Complaint volume is roughly in line with other compact cars vehicles from 2004.
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. 262 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 S60 Model Years
2004 Volvo S60: Frequently Asked Questions
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What’s in the full report?
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Get the Full 2004 Volvo S60 Report
10 sections of AI analysis based on 262 owner reports. Know before you buy.