RecallRepo

2004 Volvo S40 Recalls

Recalls on record Updated July 2026

The 2004 Volvo S40 has 6 NHTSA recall campaigns affecting an estimated 276,784 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 75 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.

Recall campaigns

EQUIPMENT 10V566000 2010-11-08 416 affected
Defect

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Consequence

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…

FUEL SYSTEM, GASOLINE 08V033000 2008-01-28 23,000 affected
Defect

ON CERTAIN VEHICLES SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA,…

Consequence

IF THIS OCCURS, THE CHECK ENGINE LIGHT MAY ILLUMINATE. IN SOME CASES, THE VEHICLE MAY FAIL TO START OR MAY STALL, INCREASING THE RISK OF A CRASH.

Remedy

DEALERS WILL REPLACE THE PEM AND INSTALL IT IN A NEW LOCATION TO PREVENT CORROSION. THE RECALL BEGAN ON FEBRUARY 20, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.

FUEL SYSTEM, GASOLINE 06V137000 2006-04-24 16,175 affected
Defect

ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH T5 TURBO ENGINES, THE POLYAMIDE TUBE IN THE FUEL LINE IS SENSITIVE TO THE EXTREME TEMPERATURES THAT MAY OCCUR IN THE AREA WHERE THE TURBO/EXHAUST MANIFOLD IS LOCATED.

Consequence

THIS MAY POTENTIALLY RESULT IN FUEL LINE LEAKAGE. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy

DEALERS WILL CHANGE THE FUEL LINE MATERIAL TO TEFLON FREE OF CHARGE. THE RECALL BEGAN ON JUNE 5, 2006. OWNERS MAY CONTACT VOLVO CARS AT 1-800-458-1552.

SERVICE BRAKES, HYDRAULIC 04V493000 2004-10-14 1,719 affected
Defect

ON CERTAIN PASSENGER VEHICLES, THE NON-RETURN VALVE MAY CRACK DUE TO A POOR WELD CAUSING A VACUUM LEAK.

Consequence

IF THIS OCCURS, MORE BRAKE PEDAL FORCE MAY BE REQUIRED TO STOP THE VEHICLE AND/OR MAY EXPERIENCE A ROUGH ENGINE IDLE, WHICH COULD RESULT IN A CRASH.

Remedy

DEALERS WILL INSPECT, AND IF NECESSARY, REPLACE THE VACUUM HOSE. THE RECALL BEGAN ON NOVEMBER 29, 2004. OWNERS SHOULD CONTACT VOLVO CARS AT 1-800-458-1552.

FUEL SYSTEM, GASOLINE 03V424000 2003-10-24 15,067 affected
Defect

ON CERTAIN SEDANS AND STATION WAGONS, THERE MAY BE A FUEL LEAK FROM THE FUEL RAIL DUE TO INADEQUATE WELDING.

Consequence

FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy

DEALERS WILL INSTALL A V-CLAMP TO THE FUEL RAIL. OWNER NOTIFICATION BEGAN ON JANUARY 28, 2004. OWNERS SHOULD CONTACT VOLVO AT 1-800-458-1552.

EQUIPMENT 03V284000 2003-08-01 220,407 affected
Defect

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE SECOND ISOFIX GUIDE WAS NOT INSTALLED IN THESE VEHICLES AND, IN CERTAIN CASES, THE OWNER'S MANUAL ISOFIX INFORMATION IS INCORRECT.

Consequence

THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Remedy

OWNERS WILL RECEIVE A LETTER/PACKAGE CONSISTING OF THE SECOND ISOFIX GUIDE WITH INSTALLATION INSTRUCTIONS, AND IN CERTAIN CASES, THE CORRECTED OWNER'S MANUAL MAY BE PROVIDED. IF THE OWNER WANTS TO TAKE THEIR VEHICLE TO A VOLVO DEALER FOR INSTALLATION OF THE GUIDE, IT WILL BE PERFORMED AT NO CHARGE TO THE OWNER. …

Complaints by component

ELECTRICAL SYSTEM
9
1fires
AIR BAGS
6
1crashes1injuries
SERVICE BRAKES, HYDRAULIC
4
1fires
AIR BAGS:FRONTAL
3
2crashes2injuries
ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL
3
ENGINE AND ENGINE COOLING:ENGINE
3
FUEL SYSTEM, GASOLINE
3
SERVICE BRAKES
3
1crashes1injuries
STEERING
3
VEHICLE SPEED CONTROL
3
1crashes
Total complaints75

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“Having a coolant leakage, crash mode and safety alarm system check keeps coming on...when crash mode comes on...car just shuts off.”

ELECTRICAL SYSTEM · reported 2020-11-01

“Having a coolant leakage, crash mode and safety alarm system check keeps coming on...when crash mode comes on...car just shuts off.”

FORWARD COLLISION AVOIDANCE: WARNINGS · reported 2020-11-01

“Tl* the contact owns a 2004 volvo s40 equipped with cooper zeon rs3-a tires, size: 205/55/16r (na). The contact heard a loud humming noise coming from the tires. The inside of the tread had a line and the contact noticed damage or an opening. An independent mechanic confirmed that the tires were…”

TIRES · reported 2018-09-01

“No collision. Srs light has been coming on since 2007. Dealership has replaced wiring, air bags and nothing helps. Srs light comes on every 7 to 12 months. This has been going on for 11 years.”

AIR BAGS · reported 2018-05-17

“The key does not turn all the way to turn the ignition - it's locked after turning I and ii (not to iii). I had to have the car towed. I could have been stranded in an unsafe area. I called volvo customer service, but I was told it's not under warranty anymore. I went to youtube as to how I could…”

ELECTRICAL SYSTEM · reported 2017-11-18

“The key does not turn all the way to turn the ignition - it's locked after turning I and ii (not to iii). I had to have the car towed. I could have been stranded in an unsafe area. I called volvo customer service, but I was told it's not under warranty anymore. I went to youtube as to how I could…”

SUSPENSION · reported 2017-11-18

“The key does not turn all the way to turn the ignition - it's locked after turning I and ii (not to iii). I had to have the car towed. I could have been stranded in an unsafe area. I called volvo customer service, but I was told it's not under warranty anymore. I went to youtube as to how I could…”

UNKNOWN OR OTHER · reported 2017-11-18

“The issue of no headlights (low-bulb failure) is dangerous & expensive. Nor is there a viable permanent repair as the "low-bulb failure" always re-occurs & has been an ongoing problem for me since my car was new. Suddenly having no headlights causes a serious & immediate safety issue for occupants…”

EXTERIOR LIGHTING · reported 2017-01-04
Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Volvo S40 as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.