Problems · NHTSA complaints
2005 Volvo S-Class problems
Owners filed 140 complaints about the 2005 Volvo S-Class with NHTSA between Dec 2004 and Mar 2024. The most-cited component is electrical system (30).
Complaints
140
Filed with NHTSA
Crashes
3
Reported by owners
Fires
2
Reported by owners
Injuries
1
People reported injured
Deaths
0
Reported to NHTSA
Complaints by component
One complaint can cite several components
- Electrical system30
- Engine and engine cooling21
- Fuel system, gasoline17
- Fuel/propulsion system16
- Engine10
- Vehicle speed control8
- Tires8
- Service brakes, hydraulic8
- Power train7
- Air bags7
- Structure7
- Visibility7
- Service brakes6
- Suspension6
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
1
23
6
4
13
7
12
14
5
9
9
7
7
8
3
4
2
3
1
1
1
View as table
| Model year | Complaints filed per calendar year |
|---|---|
| 2004 | 1 |
| 2005 | 23 |
| 2006 | 6 |
| 2007 | 4 |
| 2008 | 13 |
| 2009 | 7 |
| 2010 | 12 |
| 2011 | 14 |
| 2012 | 5 |
| 2013 | 9 |
| 2014 | 9 |
| 2015 | 7 |
| 2016 | 7 |
| 2017 | 8 |
| 2018 | 3 |
| 2019 | 4 |
| 2020 | 2 |
| 2021 | 3 |
| 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
Electrical system
30 reports1 fire1 related recall
“The contact's wife owns a 2005 Volvo S40. The contact stated the vehicle was difficult to start for several days. Eventually, the failure progressed and the vehicle was not able to start. The check engine warning light was illuminated. The vehicle was repaired by the contact, a previous Volvo technician. The contact stated the failure was due to the pump electrical module being located out of the vehicle. The contact spoke with the dealer. The contact referenced The manufacturer was made aware of the failure. The approximate failure mileage was 170,000.”
Engine and engine cooling
21 reports1 crash1 fire
“TWICE NOW OVER A TEN DAY PERIOD FIRST WHEN REDUCING SPEED TO A STOP OR THEN AGAIN AT A SPEED OF LESS THAN 5 MPH, THE CAR DIED...FIRST THE ENGINE DIED THEN ALL ELSE DIED. THE CAR WENT DEAD. I STILL HAD MY STEERING AND SLOWLY ROLLED TO THE CURBED THEN AS I GENTLY PUT ON THE BRAKES THE CAR JERKED TO A HALT. DURING THE SECOND INCIDENT THE CAR STILL JERKED AFTER I HAD STOPPED. A LOUD SOUND OF A FAN FROM THE ENGINE COULD BE HEARD. THE FAN STOPPED AFTER 10 TO 15 SECONDS. AFTER A MINUTE I RESTARTED THE CAR AND MADE IT HOME BOTH TIMES. *TR”
Fuel system, gasoline
17 reports3 related recalls
“TL* THE CONTACT OWNS A 2005 VOLVO S40. THE CONTACT STATED THAT WHILE DRIVING AT AN UNDISCLOSED SPEED, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE FUEL PUMP ELECTRONIC MODULE HAD FAILED DUE TO RUSTING AND CORROSION. THE FUEL PUMP ELECTRONIC MODULE WAS REPLACED AND THE FAILURE WAS REMEDIED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER 08V033000 (FUEL SYSTEM, GASOLINE). THE CONTACT STATED THAT THE VEHICLE HAD EXPERIENCED THE FAILURE LISTED IN THE RECALL. ADDITIONALLY, THE VEHICLE WAS ORIGINALLY SOLD IN THE STATE OF CALIFORNIA AND HAD BEEN DRIVEN IN THE STATE OF MICHIGAN THE PAST 6 YEARS. THE FAILURE MILEAGE WAS 147,000.”
Fuel/propulsion system
16 reports
“Fuel smell in and around car. Previous recall on cracked fuel pump causing odor was completed by Powell Volvo in 2010. The same defect may have happened recently as the odor was noticed in December 2021 and is now stronger. Volvo may have extended the warranty.”
Engine
10 reports1 fire
“2005 VOLVO S40 ENGINE AIR CONDITIONING MALFUNCTIONED. WHEN THE PROBLEM FIRST BEGUN THE CAR WOULD BE COOL AT START THEN GET WARM UNTIL ONE DAY THE AIR CONDITIONING JUST QUIT WORKING. I READ ON THIS FORUM AUTHORIZED VOLVO DEALERSHIP ADMITS THIS IS A COMMON PROBLEM IN THIS YEAR/MAKE/MODEL. THE COMPRESSOR CLUTCH OR COMPRESSOR OR BOTH REQUIRED REPLACING. IN A CLASS ACTION LAWSUIT [FILED 2018] HTTP://WWW.AUTOPARTSCLASS.COM/INDEX.PHP INCLUDES THE 2005 VOLVO S40 AIR CONDITIONING UNIT: [SEE BELOW] CONGRATULATIONS! YOUR 2005 VOLVO S40 IS INCLUDED IN THE FOLLOWING AUTO PARTS CASES: IN RE: INSTRUMENT PANEL CLUSTERS IN RE: AIR CONDITIONING SYSTEMS IN RE: ALTERNATORS IN RE: WINDSHIELD WIPER SYSTEMS”
Vehicle speed control
8 reports
“TL* THE CONTACT OWNS A 2005 VOLVO S80. THE CONTACT STATED WHEN VEHICLE WAS PARK THE ENGINE ACCELERATED OWN ITS OWN. THE FAILURE OCCURRED NUMEROUS OF TIMES. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY WERE UNABLE TO DIAGNOSE A FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 67,000.”
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.