The 2004 Volvo S60 has 5 NHTSA recall campaigns affecting an estimated 480,707 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 262 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
Recall campaigns
AIR BAGS21V7660002021-09-30259,383 affected
Defect
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.
Consequence
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.
EQUIPMENT10V5660002010-11-08416 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…
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…
Consequence
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 COOLING07V2260002007-06-0532,189 affected
Defect
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…
Consequence
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.
STEERING04V0290002004-01-1629,986 affected
Defect
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…
Consequence
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.
Complaints by component
ENGINE AND ENGINE COOLING
49
3crashes1injuries
ENGINE
22
1fires
FUEL SYSTEM, GASOLINE
22
ELECTRICAL SYSTEM
19
4fires
FUEL/PROPULSION SYSTEM
18
VEHICLE SPEED CONTROL
10
2crashes
ENGINE AND ENGINE COOLING:ENGINE
9
SEATS
9
9fires1injuries
STEERING
9
AIR BAGS
8
5crashes4injuries
Total complaints262
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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…”
“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…”
“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…”
“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…”
“The contact owns a 2004 volvo s60. The contact stated that while operating the vehicle, the instrument panel would not illuminate or operate. During the failure, the fuel gauge, speedometer, odometer, and other information was unavailable to the driver. The cause of the failure was not determined.…”
“Driving home from church,, smoke started coming from the drivers seat,from the heated seat. Burned a hole thru the leather . Was able to turn off the switch and put some snow into the golf size hole and pulled the fuse to the elect heat switch. No further damage was noticed .city street. The hole…”
“Yes my passenger side seat belt just randomly locked up. My car has never been in any crashes I didn't stop short for it to lock up. I went to put it on and it would only pull half way out and then when it went back it it stuck. It won't come out at all at all now. I can't pass inspection without…”
“My son was in a side impact collision on the passenger side of his 2004 volvo s60. He was in a rural area and either didn't see the oncoming car or missed his stop sign and the oncoming driver was unable to stop. The other driver is uninjured but my son in severely injured with a grade 3 dai head…”
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 S60 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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