Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.
2004 Volvo S40 recalls
Equipment: electrical, navigational system(global positioning system)
NHTSA campaign 10V566000 · reported November 8, 2010 · VOLVO CARS OF N.A. LLC. · 416 vehicles potentially affected
- The problem
- Volvo is recalling certain vehicles equipped with garmin 760 portable global positioning system (gps) units because the batteries on those units may overheat.
- The risk
- An overheated battery could lead to a fire.
- The fix
- 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.
Fuel system, gasoline: delivery, fuel pump
NHTSA campaign 08V033000 · reported January 28, 2008 · VOLVO CARS OF N.A. LLC. · 23,000 vehicles potentially affected
- The problem
- 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, reoccurring, long-term exposure to certain environmental conditions such as salty-wet conditions, it is possible for the pump electronic module (pem) to become corroded internally. This can cause a faulty signal to the fuel pump, resulting in low or no fuel pressure to the engine.
- The risk
- 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.
- The fix
- 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
NHTSA campaign 06V137000 · reported April 24, 2006 · VOLVO CARS OF N.A. LLC. · 16,175 vehicles potentially affected
- The problem
- 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.
- The risk
- This may potentially result in fuel line leakage. Fuel leakage, in the presence of an ignition source, could result in a fire.
- The fix
- 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: power assist, vacuum, hoses, lines/piping, and fittings
NHTSA campaign 04V493000 · reported October 14, 2004 · VOLVO CARS OF N.A. LLC. · 1,719 vehicles potentially affected
- The problem
- On certain passenger vehicles, the non-return valve may crack due to a poor weld causing a vacuum leak.
- The risk
- 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.
- The fix
- 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
NHTSA campaign 03V424000 · reported October 24, 2003 · VOLVO CARS OF N.A. LLC. · 15,067 vehicles potentially affected
- The problem
- On certain sedans and station wagons, there may be a fuel leak from the fuel rail due to inadequate welding.
- The risk
- Fuel leakage in the presence of an ignition source could result in a fire.
- The fix
- 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: other, labels
NHTSA campaign 03V284000 · reported August 1, 2003 · VOLVO CARS OF N.A. LLC. · 220,407 vehicles potentially affected
- The problem
- 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.
- The risk
- This does not meet the requirements of the standard.
- The fix
- 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. Owner notification began on december 19, 2003. Owners should contact volvo at 1-800-458-1552.
What owners report
Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.
Nov 8, 2020 · Electrical system · 123,713 miles
HAVING A COOLANT LEAKAGE, CRASH MODE AND SAFETY ALARM SYSTEM CHECK KEEPS COMING ON...WHEN CRASH MODE COMES ON...CAR JUST SHUTS OFF.
Oct 1, 2019 · Tires · 145,000 miles
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…
Jun 7, 2018 · Air bags · 140,000 miles
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.
Apr 10, 2018 · Electrical system
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 FIX IT AND FOUND OUT…
Jan 6, 2017 · Exterior lighting · 140,000 miles
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 OF THE CAR & FOR…
Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received November 8, 2020.