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Electrical systemPart report

2002 Volvo S40 Electrical system Problems

Complaints
5about this part
Share
19%of 27 total for the year
Median mileage
30,000miles
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.

NHTSA recorded 5 complaints about the electrical system of the 2002 Volvo S40, 19% of the 27 complaints for this model year. Where a mileage was given, the median is 30,000 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.

“In september of 2004, I began experiencing problems with my Volvo S40 sedan. The vehicle would shut off while I was operating it for no apparent reason. I took the vehicle to the dealer twice and then contacted the Volvo customer care department following an incident when the vehicle shut off while I was in a very busy intersection in town. I narrowly avoided a very serious crash. They sent a regional technician to the Volvo dealer. Volvo had the car for an extended period of time and said while they could not determine the problem, they replaced several parts. …”

NHTSA complaint #10132646, filed 2005-08, 48,000 miles

“- the contact stated that while attempting to drive the 2002 Volvo S40 he turned the key in the ignition and a thick black smoke came from the front driver side door panel and filled the interior of the vehicle immediately. The contact turned the vehicle off and exited the vehicle. The vehicle was taken to a Volvo dealer and they could not find the cause of the smoke. The current and failure mileage were 30,000.”

NHTSA complaint #10182634, filed 2007-02, 30,000 miles

“The horn failed to function properly when horn button was pressed from the left side. The horn did not work at times or excessive force was needed. Consumer was involved in a rear end collision in which he tried to use the horn but it didn't work. Vehicle was brought in several times but not repaired to working order.”

NHTSA complaint #10042382, filed 2003-11, 6 miles

“I have had to replace a headlight 3 times and a taillight 2 times, a console light, and the fuse to my cigarette lighter in my 2002 Volvo S40; 5 of these things in the last six weeks. The Volvo dealership says volvos now ( they didn't specify any particular year of volvos) are blowing headlights so frequently, that the customer reps keep headlight bulbs in their desk drawers and replace them for free. …”

NHTSA complaint #10109875, filed 2005-02

Related service bulletins

Electrical system: other model years

YearComplaintsShare of year
2011480%
2010111%
2009110%
2008425%
2007520%
20062441%
20051928%
20041123%
2003317%
2002519%
20011012%
20001311%

Other parts of the 2002 Volvo S40

Brakes
7 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 27, 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