2004 Volvo S40 Problems

Typical for Model

Real NHTSA owner complaints for the 2004 Volvo S40.

20032005
Complaints
75
Crashes
7
Fires
2
Injuries
6
Fatalities
—
Recalls
1

Worst 2004 Volvo S40 Problems

Top 3 most-reported issues with average mileage at failure.

#19 complaints

Electrical Faults

Avg mileage:50,702 mi
Fires:1
#26 complaints

Airbags

Avg mileage:103,250 mi
Crash-related:1
#34 complaints

Hydraulic Brakes

Fires:1
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All Problems by Category

Every NHTSA complaint category for the 2004 Volvo S40.

Electrical Faults
9
complaints
Crashes
—
Fires
1
Avg Miles
50,702
Airbags
6
complaints
Crashes
1
Fires
—
Avg Miles
103,250
Hydraulic Brakes
4
complaints
Crashes
—
Fires
1
Avg Miles
—
Air Bags:Frontal
3
complaints
Crashes
2
Fires
—
Avg Miles
—
Instrument Cluster
3
complaints
Crashes
—
Fires
—
Avg Miles
—
Engine And Engine Cooling:Engine
3
complaints
Crashes
—
Fires
—
Avg Miles
—
Gasoline Fuel System
3
complaints
Crashes
—
Fires
—
Avg Miles
—
Brakes
3
complaints
Crashes
1
Fires
—
Avg Miles
—
Steering Defects
3
complaints
Crashes
—
Fires
—
Avg Miles
—
Unintended Acceleration
3
complaints
Crashes
1
Fires
—
Avg Miles
—
Air Bags:Frontal:Sensor/Control Module
2
complaints
Crashes
—
Fires
—
Avg Miles
—
Engine Problems
2
complaints
Crashes
—
Fires
—
Avg Miles
—
Engine & Cooling
2
complaints
Crashes
—
Fires
—
Avg Miles
—
Headlight/Taillight Failures
2
complaints
Crashes
—
Fires
—
Avg Miles
—
Fuel Pump
2
complaints
Crashes
—
Fires
—
Avg Miles
—
Fuel System
2
complaints
Crashes
1
Fires
—
Avg Miles
—
Service Brakes, Hydraulic:Pedals And Linkages
2
complaints
Crashes
—
Fires
—
Avg Miles
—
Electrical System:12v/24v/48v Battery
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Equipment:Appliance:Air Conditioner
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Forward Collision Avoidance: Warnings
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Fuel System, Other:Storage:Fuel Gauge System
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Latches / Locks
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Latches/Locks/Linkages:Doors:Latch
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Transmission / Drivetrain
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Service Brakes, Air:Antilock
1
complaints
Crashes
1
Fires
—
Avg Miles
—
Service Brakes, Hydraulic:Foundation Components
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Service Brakes, Hydraulic:Power Assist:Hydraulic:Hoses, Lines/Piping, And Fittings
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Steering:Rack And Pinion
1
complaints
Crashes
—
Fires
—
Avg Miles
—
Body Structure
1
complaints
Crashes
—
Fires
—
Avg Miles
—

Search Owner Complaints

Read what owners actually reported to NHTSA for the 2004 Volvo S40. Type a keyword (e.g. “transmission”, “stalling”, “brakes”) to filter.

Recalls for 2004 Volvo S40

1 NHTSA recall campaign affecting ~416 vehicles.

10V566000Equipment:electrical:navigational System(global Positioning System)
~416 affected

VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.

Other Volvo S40 Years

200020012002200320042005200620072008200920102011

2004 Volvo S40 — FAQ

Answers based on real NHTSA complaint and recall data for this specific model year.

Is the 2004 Volvo S40 reliable?
Verdict: Typical for Model. The 2004 Volvo S40 has 75 NHTSA complaints, 7 crash-related, and 1 recall campaign. The most common issue is Electrical Faults with 9 complaints. Source: NHTSA via VinItel.
What are common problems with the 2004 Volvo S40?
Top reported problems: Electrical Faults (9 complaints, avg 50,702 mi); Airbags (6 complaints, avg 103,250 mi); Hydraulic Brakes (4 complaints). Every complaint is filed by an owner with NHTSA — this is raw reported data, not editorial opinion.
At what mileage do problems start on the 2004 Volvo S40?
The weighted average mileage at time of complaint is about 71,721 miles. Some components fail earlier, some later — check the "All Problems by Category" table above for per-issue averages.
How safe is the 2004 Volvo S40?
NHTSA complaints for the 2004 Volvo S40 include 7 crash-related reports, 2 fire reports, 6 injuries, and 0 fatalities. These are owner-reported incidents, not official crash-test ratings — a complaint being filed doesn't confirm a defect, but clusters around specific components are worth investigating.
Does the 2004 Volvo S40 have any recalls?
Yes — 1 NHTSA recall campaign affecting an estimated 416 vehicles. Recalls are free to fix at the dealer. Always verify by VIN whether the specific car you're looking at has had its recalls addressed.
Should I buy a 2004 Volvo S40?
Complaint levels are in line with what's expected. Normal used-car due diligence applies — check the specific VIN for accident history, open recalls, and title brands.

Source: NHTSA (National Highway Traffic Safety Administration) complaint and recall databases, aggregated by VinItel.

Wider context: See the full Volvo S40 reliability report with year-by-year comparison and generation analysis.

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