Recalls
5campaigns
1 air bag · 1 electrical · 1 fuel pump
Source: NHTSA
Complaints
198filed
Owner reports, 2000–2009 shown
Source: NHTSA ODI
Fuel economy
22mpg combined
$2,969/yr at this week's prices
Source: EPA · EIA
Specs
2.4 L 5-cyl· 5-speed automatic
8 engine and transmission configurations
Source: NHTSA vPIC
Recalls (5)
NHTSA lists 5 recall campaigns for the 2004 Volvo S60. Check whether yours was repaired with NHTSA's free VIN lookup ↗
Only NHTSA and your automaker know whether your specific car was repaired. PlainVIN shows every recall campaign listed for a model year, with the official text and how many cars have been fixed so far.
Check on NHTSA ↗Listed for 2004 Volvo S60. Not checked against your VIN.
Driver's Air Bag Inflator May Explode
Air bags · frontal · driver side · inflator module
Official NHTSA text
- Summary
- 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.
21.6% repairedof 259,383 vehicles
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 21V766000
Listed for 2004 Volvo S60. Not checked against your VIN.
760 PORTABLE AUTOMOTIVE GPS UNITS/GARMIN
Equipment · electrical · navigational system(global positioning system)
Official NHTSA text
- Summary
- 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 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.
Repair progress not yet reported416 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 10V566000
Listed for 2004 Volvo S60. Not checked against your VIN.
FUEL PUMP LEAK
Fuel system, gasoline · delivery · fuel pump
Official NHTSA text
- Summary
- 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.
- 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.
Repair progress not yet reported158,733 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 09V483000
Listed for 2004 Volvo S60. Not checked against your VIN.
FUEL PRESSURE SENSOR
Engine and engine cooling
Official NHTSA text
- Summary
- 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.
- 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.
Repair progress not yet reported32,189 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 07V226000
Listed for 2004 Volvo S60. Not checked against your VIN.
VOLVO/FRONT CONTROL ARMS
Steering · linkages
Official NHTSA text
- Summary
- 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.
- 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.
Repair progress not yet reported29,986 vehicles potentially affected
Manufacturer report to NHTSA · Source: US DOT recall completion data, retrieved Oct 6, 2026
Check your VIN on NHTSA
or ask a dealer to check campaign 04V029000
PlainVIN shows public government records for education. It isn't a vehicle inspection or legal advice. Check your own VIN with NHTSA or your dealer.
Owner complaints (198)
198 complaints filed with NHTSA (owner reports, not verified findings). The engine and engine cooling is mentioned most often.
12involved a crash
12involved a fire
8injuries reported
0deaths reported
As reported by owners in their complaints. These are reports, not NHTSA findings.
Most-reported components
| Component | Complaints | % of 198 |
|---|---|---|
| Engine and engine cooling | 63 | 31.8% |
| Fuel system | 37 | 18.7% |
| Engine | 22 | 11.1% |
| Electrical system | 21 | 10.6% |
| Fuel/propulsion system | 18 | 9.1% |
| Power train | 12 | 6.1% |
| Seats | 12 | 6.1% |
| Vehicle speed control | 11 | 5.6% |
| Air bags | 9 | 4.5% |
| Steering | 9 | 4.5% |
How 2004 compares with other S60 years
Best and worst S60 years →20001
2001223
2002186
2003120
2004198
200544
200631
200721
200810
20097
| Model year | Complaints | Recall campaigns |
|---|---|---|
| 2000 | 1 | 0 |
| 2001 | 223 | 8 |
| 2002 | 186 | 8 |
| 2003 | 120 | 6 |
| 2004 | 198 | 5 |
| 2005 | 44 | 3 |
| 2006 | 31 | 3 |
| 2007 | 21 | 2 |
| 2008 | 10 | 2 |
| 2009 | 7 | 3 |
This year (2004)Other yearsStill collecting reports
Counts are owner reports, not failure rates. Higher sales years tend to draw more reports. Owners are still filing reports for recent model years, so these counts will grow. Source: NHTSA ODI, retrieved Oct 6, 2026.
Fuel economy: up to 22 mpg combined
22
mpg combined
19
city
28
highway
- EPA annual fuel cost
- $3,750
- CO₂ tailpipe
- 404 g/mi
- EPA class
- Compact Cars
What it costs you to run
$2,969per year
$247per month
682gallons a year
Miles ÷ 22 mpg × $4.354 (EIA US average regular, week of Oct 5, 2026, all taxes included). Source: EPA · EIA.
EPA label estimates from lab tests; your mileage will vary.
Specs by configuration
| Engine · transmission | Drive | City / Hwy / Comb | EPA $/yr | CO₂ g/mi |
|---|---|---|---|---|
| 2.4 L 5-cyl · 5-speed automatic | Front-Wheel Drive | 19 / 28 / 22 | $3,750 | 404 |
| 2.4 L 5-cyl · 5-speed manual | Front-Wheel Drive | 19 / 27 / 22 | $3,750 | 404 |
| 2.5 L 5-cyl · 5-speed automatic | Front-Wheel Drive | 19 / 27 / 22 | $3,750 | 404 |
| 2.3 L 5-cyl · 5-speed manual | Front-Wheel Drive | 18 / 25 / 21 | $3,900 | 423 |
| 2.3 L 5-cyl · 5-speed automatic | Front-Wheel Drive | 18 / 26 / 21 | $3,900 | 423 |
| 2.5 L 5-cyl · 5-speed automatic | 4-Wheel or All-Wheel Drive | 18 / 25 / 20 | $4,100 | 444 |
| 2.5 L 5-cyl · 6-speed manual | 4-Wheel or All-Wheel Drive | 16 / 23 / 19 | $4,350 | 468 |
| 2.5 L 5-cyl · 5-speed automatic | 4-Wheel or All-Wheel Drive | 16 / 23 / 19 | $4,350 | 468 |
Source: EPA fuel economy data, retrieved Oct 6, 2026. Configurations are listed when EPA and NHTSA records match.
Looking at a 2004 S60 for sale?
Print a one-page buyer's checklist: each recall campaign with a box to tick when the seller shows proof of repair, the top complaint areas to inspect, crash stars, MPG, and a link back to this page.
Where to next
2004 Volvo S60 FAQ
How many recalls does the 2004 Volvo S60 have?
NHTSA lists 5 recall campaigns: 21V766000 (air bag), 10V566000 (electrical), 09V483000 (fuel pump), 07V226000 (engine), 04V029000 (steering). Use NHTSA's VIN lookup to see whether a specific car was repaired.
What are the most common 2004 Volvo S60 problems?
Owners filed 198 complaints with NHTSA. Engine and engine cooling (63), Fuel system (37), Engine (22) are mentioned most. These are owner reports, not verified findings.
What mpg does the 2004 Volvo S60 get?
EPA rates the 2.4 L 5-cyl · 5-speed automatic version at 19 city, 28 highway and 22 combined mpg. Other configurations are listed in the fuel economy section.
How does the 2004 S60 compare with other years?
Among the 2000–2009 Volvo S60 model years at least five years old, the 2000 drew the fewest complaints (1) and the 2001 the most (223). The 2004 drew 198. Counts are owner reports, not failure rates.
How this page was madeSources, processing, limits, review and changes
Data sources
- NHTSA recalls by vehicle
Retrieved Oct 6, 2026 - US DOT recall completion rates (data.transportation.gov)
Retrieved Oct 6, 2026 - NHTSA ODI owner complaints
Retrieved Oct 6, 2026 - NHTSA NCAP 5-Star Safety Ratings
Retrieved Oct 6, 2026 - EPA fuel economy data (licence confirmation pending)
Retrieved Oct 6, 2026 - EIA weekly retail gasoline prices
Weekly, all taxes included
Processing
- Complaints are counted per component. One complaint can list several, so component totals add up to more than the total.
- Fuel cost = miles per year ÷ EPA combined mpg × EIA weekly price for your region.
Limitations
- Complaint counts are owner reports, not verified findings or failure rates. There is no sales denominator.
- Recall campaigns are listed for the model year. Only NHTSA and the automaker know whether a specific car was repaired.
- Recent model years are still collecting reports.
Review
Data compiled automatically from the official files listed here.
Changelog
- 2026-10-06 Data refreshed from the official files.
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