2002 Volvo S40 Brakes Problems
- Complaints
- 7about this part
- Share
- 26%of 27 total for the year
- Median mileage
- 104,000miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 7 complaints about the brakes of the 2002 Volvo S40, 26% of the 27 complaints for this model year. Where a mileage was given, the median is 104,000 miles. 1 of these say a crash was involved, according to the filers.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“I was driving on a main road and my brakes failed. It was determined that a brake line corroded through. It appears that the vehicle has a single master brake cylinder. I asked a Volvo dealership about this, and they confirmed to me that the master brake cylinder is a single one. It is my understanding that in the 80's, all vehicles sold in the united states were to have a dual master brake cylinder.”
NHTSA complaint #10550701, filed 2013-11, 145,000 miles“The rear brake pads on my 2002 S40 Volvo wore out at about 21 thousand miles and ruined the rotor. According to Volvo corp. This is becasue the government is has prohibited them from using asbestos in the brake pads. Volvo put noise making squealeres on the inside pads but due to the design of the brakes the outside pads wear out first causing a rivit on the pad to contact the rotor and ruin it before the pads can be replaced. …”
NHTSA complaint #10030802, filed 2003-08, 21,000 miles“Types of recurring issues with Volvo S40: headlights, driver front window motor, early brake pad wear. Headlight bulbs were replaced 2-3 times a year at consumer's cost. When brought to the attention of Volvo dealer they reported that it was probably due to lights being used during daylight. They check electrical and reported no issue. Had brake pad and rotor issued shortly after purchasing the vehicle. Volvo dealer reported Volvo rotors were built thin and soft. Cost of brake replacement was not covered under warranty as it was considered regular wear. …”
NHTSA complaint #10191517, filed 2007-05, 2,000 miles“I was slowing down on the interstate for my exit and my steering wheel starting shaking severely to the point that I was barely able to contain it this was when I decided to take my S40 to the dealership. I had noticed some shaking previously but wasn't sure what the problem was and since my car had just been serviced I figured anything serious would have been identified. When I took my car in I was told that I needed new rotors and pads. My mileage seemed rather low for my rotors to be shot so I asked why this might have happened as I work from home. …”
NHTSA complaint #10105803, filed 2005-01“The contact owns a 2002 Volvo S40. While driving 30 MPH the contact engaged the brakes when the vehicle in front of her slowed down causing a crash. The vehicle failed to slow down when the brakes were applied. The contact was not injured. A police report was filed. The contacts vehicle had front end damages. The vehicle was repaired. The contact stated that a local mechanic replaced all of the left front lights, the hood, the bumper and the fender. The failure mileage was 104,000 and the current mileage was 104,900.”
NHTSA complaint #10375160, filed 2011-01, 104,000 milesRelated service bulletins
- 10157889Feb 14, 2019This is a Technical Journal: When sensitive information, like vehicle speed, brake usage, etc. (customer behavoiur information) of a car is required from Volvo Car Corporation…
- 10167828Dec 3, 2016This is a Technical Journal: When sensitive information, like vehicle speed, brake usage, etc. (customer behavoiur information) of a car is required from Volvo Car Corporation…
Brakes: other model years
Other parts of the 2002 Volvo S40
5 complaintsEngine cooling
3 complaintsExterior lighting
3 complaintsSuspension
3 complaintsAir bags
2 complaintsFuel system
2 complaintsTransmission and drivetrain
2 complaintsVisibility (wipers, defrost, mirrors)
2 complaintsOther or unknown
1 complaintsSeat belts
1 complaintsVehicle speed control
1 complaints
← All problems reported for the 2002 Volvo S40
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology