2004 Volvo S40 problems & reliability
48 owner complaints filed with NHTSA for the 2004 Volvo S40, alongside 6 safety recall campaigns. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
4 complaints report injuries (4 injured).
Federal crash records (FARS 2020–2023): 2004 Volvo S40 vehicles were involved in 2 fatal crashes with 0 occupant deaths. Involvement counts are not adjusted for how many are on the road and do not imply fault or a vehicle defect.
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Air Bags → | 11 | 23% |
| Electrical System → | 11 | 23% |
| Service Brakes, Hydraulic | 8 | 17% |
| Engine and Engine Cooling | 5 | 10% |
| Fuel System, Gasoline | 5 | 10% |
| Steering | 4 | 8% |
| Vehicle Speed Control | 4 | 8% |
| Service Brakes | 3 | 6% |
| Engine | 2 | 4% |
| Exterior Lighting | 2 | 4% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Mileage when problems occurred
Half of the failures with a reported odometer reading occurred by 64,500 miles (middle 50% between 37,878 and 96,500 miles), based on 34 complaints that included mileage.
Complaints by incident year
What owners report
“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 · filed Nov 8, 2020
“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 separating at the…”
Tires · filed Oct 1, 2019
“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 · filed Jun 7, 2018
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Technical service bulletins
238 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 2004 Volvo S40. The 10 most recent:
This is a Technical Journal: Text plus 2 PDFs and 1 .PNG Oil Consumption test. Perform the test. Follow service procedure Description and Service sections updated to clarify that vehicle reports are not…
35526.1.8 · Service Bulletin/Repair Instructions · issued Apr 23, 2026
This is a TJ text only - The purpose of this TJ is to be a master reference list to easily identify any components that are on prior approval. This TJ will be regularily updated as items are added or removed from prior…
37809.1.1 · Service Bulletin/Repair Instructions · issued Apr 7, 2026
This is a Technical Journal. Vehicle type and platform identification.
19245 · Service Bulletin/Repair Instructions · issued Dec 6, 2025
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between…
8501 · Service Bulletin/Repair Instructions · issued Apr 10, 2025
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that…
S10303 · Service Campaign · issued Feb 21, 2025
Volvo Cars USA LLC and Volvo Car Canada LTD on behalf of the Volvo Car Corporation has decided to launch Service Action S10303 on certain model year 2025 EX90 vehicles. Volvo Car Investigations have identified that…
S10303 · Service Campaign · issued Feb 13, 2025
This is a Technical Journal: Vehicle/Connectivity report checklist. To provide timely and high-quality feedback to the appropriate department or factory
37175 · Service Bulletin/Repair Instructions · issued Jan 16, 2025
This is a Technical Journal: Remote connection, BOMGAR application. Before joining a remote session: •Connect a suitable battery maintainer/charger and verify that the battery voltage indicated in VIDA is between…
8501 · Service Bulletin/Repair Instructions · issued Jan 16, 2025
Information about valid Software partnumbers to order and download Software for "PDS" Pre-Delivery Service
TJ27536.21.1-2024-08-07 · Other · issued Aug 14, 2024
This is a Technical Journal: 12V Battery Testing Method
26745.13.14 · Service Bulletin/Repair Instructions · issued Jan 12, 2024
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
The 2004 Volvo S40 has 6 NHTSA recall campaigns — recall repairs are free at franchised dealers regardless of the vehicle’s age.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 2004 Volvo S40?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.
- · Owners most often reported problems around 64,500 miles — budget accordingly if the car is approaching that mileage.