2% of complaints about the 2004 Volvo S60 came in the first year, which is unremarkable for a 2004 vehicle — around the middle of the 236 model-years on record. The median complaint arrives at 7.1 yr in service. The most-reported system is engine cooling (60 complaints), typically at 6.4 yr or about 78,000 miles.
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.
An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
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.
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.
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.
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.
CERTAIN CARDONE MASTER CYLINDERS WITH PART NUMBERS 10-2925, 10-2987, 10-2987MZA, 10-3083, 11-3015, 11-3042, 11-3044, 11-3045, 11-3047, 11-3064, AND 11-3156, AND WITH DATE CODES LOWER THAN DCA7078 SOLD AS REPLACEMENT EQUIPMENT FOR USE ON THE VEHICLES LISTED ABOVE. THE SEAL ON MASTER CYLINDER CAN FAIL AND LEAK BRAKE FLUID.
LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH.
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.
THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.
BULBS CONTINUOUSLY BURNS OUT CAUSING ERRORS THAT CANNOT BE READILY FIX BY THE OWNER. BULBS SUCH AS FOR HEADLIGHTS, TURN SIGNALS AND REAR LIGHTS BURN OUT CONSTANTLY. WE ARE AVERAGING A BULB REPLACEMENT EVERY 2 MONTHS. *TR
2004 VOLVO S60 IGNITION KEY FAILURE: KEY REFUSED TO TURN CAR WILL NOT START. CAR WILL NOT GO IN TO NEUTRAL. CAR MUST BE ABANDONED OCCUPANTS MUST SEEK TRANSPORTATION. FIRST OCCURRENCE APRIL 17TH 2008. SECOND OCCURRENCE JULY 5TH. 2010. CAR TOWED TO DEALER AND IGNITION LOCK REPLACED BOTH TIMES. TOTAL COST $1662.48. *TR
VOLVO S60R SEAT ISSUE. TURNED SEAT HEATER ON, FELT VERY WARM SENSATION ON MY LEFT HIP/LEG AFTER A FEW MINUTES. TURNED SEAT HEATER OFF AND GOT OUT OF CAR TO CHECK WHAT WAS HAPPENING. SEAT HEATER BURNED THROUGH THE LEATHER AND ALSO MY JEANS. IS THERE A RECALL/FIX? SEEMS EXTREMELY DANGEROUS. *TR
STRONG FUEL ODOR EMITTING FROM PASSENGER SIDE OF VEHICLE. OBSERVED GAS STAINS COVERING OUTSIDE OF GAS TANK. RETURNED TO DEALER AND DEALER REPLACED FUEL PUMP. SINCE THEN, NO ODORS. HOWEVER, AUTO CONTINUES TO HESITATE WHEN DRIVING. IN ONE INSTANCE, CAR STALLED IN HEAVY TRAFFIC AND WAS NEARLY REAR ENDED. *TR