Problems · NHTSA complaints
2004 Volvo S-Class problems
Owners filed 298 complaints about the 2004 Volvo S-Class with NHTSA between Oct 2003 and Jul 2024. The most-cited component is engine and engine cooling (73).
Complaints
298
Filed with NHTSA
Crashes
21
Reported by owners
Fires
13
Reported by owners
Injuries
14
People reported injured
Deaths
0
Reported to NHTSA
Complaints by component
One complaint can cite several components
- Engine and engine cooling73
- Electrical system37
- Fuel system, gasoline36
- Fuel/propulsion system33
- Engine27
- Air bags24
- Steering20
- Power train17
- Vehicle speed control17
- Tires13
- Service brakes, hydraulic13
- Seats12
- Exterior lighting11
- Suspension9
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Data from NHTSA Complaints API · synced Oct 28, 2026NHTSA vehicle page
When complaints were filed
Does it get worse with age? Complaints per calendar year filed
2
9
11
12
18
28
21
43
36
22
15
22
19
12
11
4
1
5
4
1
1
1
View as table
| Model year | Complaints filed per calendar year |
|---|---|
| 2003 | 2 |
| 2004 | 9 |
| 2005 | 11 |
| 2006 | 12 |
| 2007 | 18 |
| 2008 | 28 |
| 2009 | 21 |
| 2010 | 43 |
| 2011 | 36 |
| 2012 | 22 |
| 2013 | 15 |
| 2014 | 22 |
| 2015 | 19 |
| 2016 | 12 |
| 2017 | 11 |
| 2018 | 4 |
| 2019 | 1 |
| 2020 | 5 |
| 2021 | 4 |
| 2022 | 1 |
| 2023 | 1 |
| 2024 | 1 |
Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.
Top problems in owners’ words
Verbatim from NHTSA complaints, newest first
Engine and engine cooling
73 reports3 crashes1 related recall
“2004 VOLVO S60R, EXPERIENCE TOTAL ENGINE SHUTDOWN AT APPROXIMATELY 30 MPH THE VEHICLE JUST QUIT RUNNING. CW A DIAGNOSTIC INVESTIGATION BY THE DEALER, CONFIRMED THE FUEL PRESSURE SENSOR WAS AT FAULT. THE SENSOR WAS REPLACED AT A COST OF $ 420.69. THE CONSUMER INQUIRED ABOUT A RECALL. HOWEVER, HE WAS INFORMED HIS VEHICLE WAS NOT INCLUDED IN RECALL # 07V226000. *JB”
Electrical system
37 reports5 fires
“2004 VOLVO S60 PURCHASED THE CAR USED IN SEPT 04. On 7/8/24 STRANDED AT 7-11 CAR WOULDN'T START. ACTING AS IF THERE WAS POWER LOSS, AC WENT OFF, BRAKE FAILURE LIGHT ON PANEL, POWER WINDOWS AND LOCKS DID NOT WORK, TEMP 105 OUTSIDE , THEN DRIVER PANEL WENT BLACK., I WAS SCARED. ENGINE WOULDN'T START. FINALLY, AFTER WAITING 10 MINUTES...IT STARTED RUNNING BUT WAS SLUGGISH. RADIO WAS ON, POWER DOOR, LOCKS, AND WINDOWS, DID NOT WORK. CUT THE CAR OFF AND BACK ON, ALL POWER RETURNED, NOW CHECK ENGINE AND AIR BAG TROUBLE ON PANEL. CALLED VOLVO DEALER NEXT DAY NEAR MY HOME, THEY CAN NOT SEE MY CAR TIL NEXT WEEK TUESDAY. CAN NOT ACCESS ENGINE BOX, MUST GO TO DEALER.”
Fuel system, gasoline
36 reports1 crash4 related recalls
“MY CAR WAS DYING ON THE HIGHWAY OR ON A REGULAR STREET ROAD. ENDED UP BEING THE FUEL PRESSURE SENSOR WHICH IS ON THE RECALL LIST BUT DIDN'T COME UP FOR MY VIN. I WAS DEALING WITH THIS FOR 6 MONTHS OR SO AND IT WAS VERY DANGEROUS. I DON'T UNDERSTAND WHY MY CAR ISN'T ON THE RECALL LIST. ANY HELP IS APPRECIATED. [XXX] *TR”
Fuel/propulsion system
33 reports1 crash
“Starting Sunday November 27 my car started dripping gasoline on the floor, on the driver side near the rear wheel. Immediately I took it to Volvo dealer Wynne in Hampton, VA. The service specialist told me there was not any existing recall for that issue and let me go. That night I put under the leak a flat pan. That night I collected one gallon in about 8 hours. I called Volvo cars USA [XXX] explained me the car have been fixed for the campaign #09V483000 in September 14, 2010. I own the car since 2015. I asked her if the recall should be possible to do it again at no cost for me, because it falls under Safety due to the fact the car may get in fire due to the leak of gas. She asked me to go back again to Wynne Volvo dealer and tell to the service specialist that I talked to them and if they wouldn't repair my car I could open a case with Volvo Cars USA. The service specialist told me I could leave the car for inspection, but I would be responsible for at least $180 to get and estimate, but never said that they would fix it under the safety recall number 09V483000 for vehicles sold or registered in the states with hot climate like Virginia. The recall started…”
Engine
27 reports1 fire
“TL* THE CONTACT OWNS A 2004 VOLVO S60. THE CONTACT STATED THAT WHILE STATIONARY, THE ENGINE CAUGHT FIRE. THE CONTACT STATED THAT SMOKE ENTERED INTO THE CABIN OF THE VEHICLE. THE CONTACT EXITED THE VEHICLE AND OPENED THE HOOD, AND THE ENGINE WAS SURROUNDED BY FLAMES. A POLICE OR FIRE DEPARTMENT REPORT WAS NOT FILED. AN INDEPENDENT MECHANIC EXTINGUISHED THE FIRE. THERE WERE NO INJURIES SUSTAINED. A DEALER WAS NOT MADE AWARE OF THE FIRE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FIRE. THE FAILURE MILEAGE WAS APPROXIMATELY 30,000.”
Air bags
24 reports10 crashes1 related recall
“ON 11/17/2020 WAS DRIVING TO PICK UP DECAL FOR MY CAR AND I GOT A MESSAGE THAT READ A CHECK AIRBAGS I DIDN'T HAVE ANY READING ON MY GAGES TURN SIGNAL FOR RIGHT TURN STAY LIT UP NOT BRINKING JUST ON , WHEN I STOPPED AND WENT IN BUILDING TO GET DECAL CAME BACK TO CAR STARTED IT MY GAGES CAME BACK WHICH WAS GLAD THEY WERE WORKING BUT STILL HAD MESSAGE ABOUT AIRBAGS”
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 28, 2026
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.