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Recalls are issued for a make, model and model year. Whether the repair has already been done on one specific car is known only to its manufacturer and dealers. Check your vehicle's official status at nhtsa.gov/recalls or with a dealer.
US recalls (5)
Air bags: frontal, driver side
Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Risk and remedy
Risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Remedy: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10125.
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.
Risk and remedy
Risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
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.
Risk and remedy
Risk: IF THE CONDITION OCCURS VEHICLE OWNERS MAY NOTICE FUEL SMELL AND/OR FUEL LEAK WHICH, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT THE FUEL PUMP INSTALLED IN THE VEHICLE, AND IF NECESSARY REPLACE THE FUEL PUMP WITH A PART OF A MODIFIED DESIGN. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON JANUARY 15, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
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.
Risk and remedy
Risk: MISFIRE MAY OCCUR DURING DRIVING THAT, IN TURN, WILL REDUCE THE ENGINE TORQUE AND IN THE WORST CASE SCENARIO, THE ENGINE MAY STALL WITHOUT WARNING. IN CERTAIN TRAFFIC SITUATIONS THIS COULD CAUSE AN UNSAFE SITUATION AND POSSIBLY A CRASH.
Remedy: DEALERS WILL REPLACE THE FUEL PRESSURE SENSOR FREE OF CHARGE. THE RECALL BEGAN ON JUNE 29, 2007. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
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.
Risk and remedy
Risk: THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL INSTALL A NEW TYPE OF NUT. OWNER NOTIFICATION BEGAN ON FEBRUARY 16, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.
Canadian recalls (4)
Show 4 Canadian recalls
Accessories
2010-11-08 · campaign 2010-396 · 87 vehicles
On certain vehicles, there is a possibility of overheating issues of batteries in the Garmin nüvi® 760 when certain batteries manufactured within a limited date code range are used in certain Garmin nüvi® 760 models with a specific printed circuit board (PCB) design. The interaction of these factors can, in some circumstances, increase the possibility of overheating, which may lead to a fire. Correction: Dealers will direct customers who have an affected unit to the Garmin Web site, which explains how to verify if their units are involved and includes procedures to follow for product exchange.
Fuel system
2007-05-24 · campaign 2007-167
On certain vehicles, the fuel pressure sensor may at times transmit an incorrect signal to the Engine Control Module (ECM). 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. An engine misfire may occur, reducing available engine torque and possibly causing the engine to stall. In certain traffic situations this could cause an unsafe situation and possibly a crash. Correction: Dealers will replace the fuel pressure sensor.
Suspension
2004-01-19 · campaign 2004-017
On certain vehicles, the front lower control arms may not have been manufactured within the agreed specifications and as a result the stud and nut that secure the control arm to the spindle may lose its initial axial tension. In the worst case, this condition could eventually lead to separation between the front control arm and the spindle possibly causing a loss of control and a crash. Correction: Dealer will install a new type of nut with increased assembly torque.
Other
2003-09-12 · campaign 2003-226
Certain vehicles do not comply with CMVSS 210.2. The symbol indicating the presence of a lower universal anchorage system, and a reproduction of this symbol were omitted from the owner's manual. Correction: The corrected owner's manual page will be mailed to owners.
Owner complaints (198)
Owners filed 198 complaints with NHTSA about the 2004 Volvo S60 (12 crashes, 12 fires, 8 injuries reported). Among 24 model years of this model, it ranks #2 for the most complaints (median 25).
| Most-reported problem | Complaints | |
|---|
| Engine and engine cooling | 63 | |
| Fuel system, gasoline | 30 | |
| Engine | 22 | |
| Electrical system | 21 | |
| Fuel/propulsion system | 18 | |
| Power train | 12 | |
| Seats | 12 | |
| Vehicle speed control | 11 | |
Crash test ratings
NHTSA 5-Star Safety Ratings for the 2004 Volvo S60.
| Version | Overall | Frontal | Side | Rollover |
|---|
| 2004 Volvo S60 4-DR. w/SAB | – | – | – | 5★ |
Fuel economy
EPA ratings for each 2004 Volvo S60 version.
| Version | City MPG | Highway MPG | Combined | Yearly fuel cost |
|---|
| S60 AWD 2.5 L Automatic 5-spd | 18 | 25 | 20 | $4,100 |
| S60 FWD 2.3 L Manual 5-spd | 18 | 25 | 21 | $3,900 |
| S60 FWD 2.3 L Automatic (S5) | 18 | 26 | 21 | $3,900 |
| S60 FWD 2.4 L Automatic 5-spd | 19 | 28 | 22 | $3,750 |
| S60 FWD 2.4 L Manual 5-spd | 19 | 27 | 22 | $3,750 |
| S60 FWD 2.5 L Automatic 5-spd | 19 | 27 | 22 | $3,750 |
| S60 R AWD 2.5 L Manual 6-spd | 16 | 23 | 19 | $4,350 |
| S60 R AWD 2.5 L Automatic (S5) | 16 | 23 | 19 | $4,350 |
Need this data in your app?
Recalls, complaints, crash ratings and fuel economy as a JSON API. Decode up to 50 VINs per call and get a daily feed of new recalls.
Explore the API →Sources: NHTSA recalls, complaints and 5-Star Safety Ratings, US EPA fuel economy and Transport
Canada's Vehicle Recalls Database (contains information licensed under the Open Government Licence – Canada).
Recalls updated 2026-10-30.