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2004 VOLVO S60

6 recalls Risk Grade: B+ Most severe issue: Critical

All recalls are free to repair at your local dealership. Contact your dealer to schedule service.

Known Safety Recalls

Critical #09V483000 Plain English
Component

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Manufacturer
VOLVO CARS OF N.A. LLC.
What Happened
The fuel pump in your vehicle is a critical part that delivers gasoline from the tank to your engine. In some 2001-2005 Volvo models, extreme temperatures and varying fuel types can cause the pump's metal flange to crack over time.
Risk if Unfixed
If the flange cracks, you might notice a fuel smell or a fuel leak. If this happens near an ignition source, it could lead to a fire.
Free Fix
Your Volvo dealer will inspect the fuel pump and replace it with a redesigned, more durable version at no cost to you. Schedule an appointment as soon as possible to get this free repair.
Show original NHTSA language
Original — What Happened
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.
Original — Risk if Unfixed
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.
Original — 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.
View full recall details → Repairs are free at any authorized dealer. Find a dealer →
Critical #07V226000 Plain English
Component

ENGINE AND ENGINE COOLING

Manufacturer
VOLVO CARS OF N.A. LLC.
What Happened
The fuel pressure sensor in your vehicle is a small computer that checks the pressure of the fuel system. It's located near the fuel rail and might send incorrect signals to your engine if the soldering gets damaged.
Risk if Unfixed
If this happens, your engine could misfire, which would reduce its power and, in extreme cases, cause it to stall without warning. This could be especially hazardous in heavy traffic or when merging onto a busy road.
Free Fix
Your Volvo dealer will swap out the faulty fuel pressure sensor with a new one, free of charge. This repair is complimentary, and you should schedule it as soon as you receive the recall notice.
Show original NHTSA language
Original — What Happened
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.
Original — Risk if Unfixed
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.
Original — 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.
View full recall details → Repairs are free at any authorized dealer. Find a dealer →
Critical #07E023000 Plain English
Component

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER

Manufacturer
CARDONE INDUSTRIES, INC.
What Happened
The master cylinder is a critical part of your vehicle's brake system. It's the component that helps control the brake fluid that makes your brakes work. In some cases, the seal on this part can fail, causing it to leak brake fluid.
Risk if Unfixed
If brake fluid leaks out, your brakes won't work properly. This means you might not be able to stop your vehicle as quickly or safely as you need to, which could lead to a crash.
Free Fix
Cardone will give you a full refund for any faulty master cylinder your dealer has installed, free of charge. You'll need to contact Cardone at 1-800-777-4780 to get the process started. The recall began in April 2007.
Show original NHTSA language
Original — What Happened
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.
Original — Risk if Unfixed
LOSS OF BRAKE FLUID CAN RESULT IN POOR BRAKING PERFORMANCE, POSSIBLY RESULTING IN A VEHICLE CRASH.
Original — Remedy
CARDONE WILL NOTIFY OWNERS AND OFFER TO REPURCHASE ANY DEFECTIVE MASTER CYLINDERS. THE RECALL BEGAN DURING APRIL 2007. OWNERS CAN CONTACT CARDONE AT 1-800-777-4780.
View full recall details → Repairs are free at any authorized dealer. Find a dealer →
Critical #04V029000 Plain English
Component

STEERING:LINKAGES

Manufacturer
VOLVO CARS OF N.A. LLC.
What Happened
Your vehicle's front control arms may not have been made correctly, which could affect how well the steering responds.
Risk if Unfixed
If left unfixed, this could lead to a crash due to loss of steering control and possible separation of the control arm and spindle.
Free Fix
You should take your vehicle to the dealership, where they will replace the old nut with a new one at no charge to you.
Show original NHTSA language
Original — What Happened
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.
Original — Risk if Unfixed
THIS DRIVING CONDITION COULD EVENTUALLY LEAD TO SEPARATION BETWEEN THE FRONT CONTROL ARM AND THE SPINDLE, WHICH COULD RESULT IN A CRASH.
Original — 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.
View full recall details → Repairs are free at any authorized dealer. Find a dealer →
High Priority #21V766000 Plain English
Component

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Manufacturer
Volvo Car USA, LLC
What Happened
The air bag in your driver's seat is a safety feature that inflates to protect you in a crash. In some 2001-2009 S60 and 2001-2006 S80 Volvo models, the air bag's inflator can degrade over time and explode when it's supposed to deploy.
Risk if Unfixed
If the air bag inflator explodes, it could send sharp metal fragments flying towards you or other passengers, which could cause serious injury or even be fatal.
Free Fix
Your Volvo dealer will replace the faulty air bag with a new one, at no cost to you. You should schedule this repair as soon as possible, especially if you live in a humid climate or have driven your vehicle in extreme temperatures.
Show original NHTSA language
Original — What Happened
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.
Original — Risk if Unfixed
An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Original — 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.
View full recall details → Repairs are free at any authorized dealer. Find a dealer →
Moderate #10V566000 Plain English
Component

EQUIPMENT:ELECTRICAL:NAVIGATIONAL SYSTEM(GLOBAL POSITIONING SYSTEM)

Manufacturer
VOLVO CARS OF N.A. LLC.
What Happened
Your car's Garmin GPS is a portable device that helps you navigate. In some cases, the battery inside this device can overheat.
Risk if Unfixed
If the battery overheats, it could catch fire, which is a serious safety risk.
Free Fix
Your dealer will replace the battery and add a protective spacer to prevent future overheating, all at no cost to you. You should contact your dealer to schedule the repair as soon as possible.
Show original NHTSA language
Original — What Happened
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Original — Risk if Unfixed
AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Original — 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.
View full recall details → Repairs are free at any authorized dealer. Find a dealer →

Browse by Component

FUEL SYSTEM, GASOLINE
1 recall
ENGINE AND ENGINE COOLING
1 recall
SERVICE BRAKES, HYDRAULIC
1 recall
STEERING
1 recall
AIR BAGS
1 recall
EQUIPMENT
1 recall

Other VOLVO S60 Years

2025
2 recalls
2024
3 recalls
2023
6 recalls
2022
4 recalls
2021
3 recalls
2020
4 recalls
2019
4 recalls
2018
1 recall
2017
5 recalls
2016
4 recalls
2015
2 recalls
2014
3 recalls
2013
4 recalls
2012
8 recalls
2011
6 recalls
2009
3 recalls
2008
2 recalls
2007
2 recalls
2006
4 recalls
2005
4 recalls
2003
7 recalls
2002
9 recalls
2001
9 recalls

Related Pages

2003 VOLVO S60 Recalls 2005 VOLVO S60 Recalls All VOLVO Recalls VOLVO S60 Recall History