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
01 —By component

Complaints by component

One complaint can cite several components
  1. Electrical system30
  2. Engine and engine cooling21
  3. Fuel system, gasoline17
  4. Fuel/propulsion system16
  5. Engine10
  6. Vehicle speed control8
  7. Tires8
  8. Service brakes, hydraulic8
  9. Power train7
  10. Air bags7
  11. Structure7
  12. Visibility7
  13. Service brakes6
  14. 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
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
20041
200523
20066
20074
200813
20097
201012
201114
20125
20139
20149
20157
20167
20178
20183
20194
20202
20213
20221
20231
20241

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.

03 —Owner reports

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.”
Owner complaint to NHTSAFiled Mar 20, 2024Power train, Electrical system, Fuel/propulsion systemODI 11578530

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”
Owner complaint to NHTSAFiled Apr 27, 2015Engine and engine cooling, Fuel/propulsion systemODI 10713001

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.”
Owner complaint to NHTSAFiled Mar 18, 2021Fuel system, gasolineODI 11403711

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.”
Owner complaint to NHTSAFiled Jan 7, 2022Fuel/propulsion systemODI 11446561

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”
Owner complaint to NHTSAFiled Aug 23, 2019EngineODI 11246021

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.”
Owner complaint to NHTSAFiled Aug 6, 2014Vehicle speed controlODI 10619365
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.