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Volvo S40Model year report

2004 Volvo S40 Problems

Complaints
48filed with NHTSA
Median mileage
64,000miles, 35 complaints with mileage
Recalls
6campaigns on record
Trend
FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA crash rating
—overall rating starts with 2011 models
EPA fuel economy
22 mpgcombined, 1.9L 4-cyl FWD · 19 city / 27 hwy

Sources: NHTSA records for the 2004 Volvo S40 (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error

NHTSA recorded 48 consumer complaints for the 2004 Volvo S40. The part named most often is brakes, with 12 complaints (25% of the total), followed by air bags (11) and electrical system (11). 35 of the complaints include a mileage, and 40% of those were filed for vehicles with under 50,000 miles; the median is 64,000 miles. Of all complaints, 5 involved a crash, 1 a fire, 4 an injury, according to the filers. NHTSA lists 6 recall campaigns and 235 technical service bulletins for this model year. Brakes complaints overlap with 1 recall campaign covering the hoses, lines/piping, and fittings and 12 technical service bulletins filed under the same part. Air bags complaints overlap with 6 technical service bulletins filed under the same part.

Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.

Which parts are reported most

Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.

Also reported: Other or unknown (2), Body and structure (2), Visibility (wipers, defrost, mirrors) (2), Equipment (1), Forward collision avoidance (1), Suspension (1), Tires (1), Transmission and drivetrain (1).

Example complaints

Brakes: “Brake pedal is too close to accelerator pedal. Whenever I operate the gas pedal, the side of my shoe also activates the brake. The problem is aggravated by the center tunnel carpet intruding on the minimal accelerator pedal space.”

NHTSA complaint #10908871, filed 2016-09, 42,000 miles

Air bags: “During a frontal drivers side crash the drivers side airbag did not deploy causing injury to the driver. However the passenger side airbag did deploy, but no passengers were present at the time of the accident. The impact of the crash was mostly drivers side. I also believe the braking system failed since my car failed to slow like a car should during braking.”

NHTSA complaint #10130085, filed 2005-07, 19,215 miles

Electrical system: “When driving my car, he start going faster without pressing a gas pedal when I press the brake the car turn off, I put the gear changing on park and start the car again, the RPM start going crazy, the car have only 30000 miles.”

NHTSA complaint #10307236, filed 2010-02, 29,500 miles

Fuel system: “Car is stalling out while driving down the road engine light came on when put on machine error given is fuel pressure. The fuel pressure was checked and was at correct pressure for the car. I have replaced fuel censer and car ran fine for 2 days then same issue with same error the fuel controller has a corroded pen I tried to call Volvo they are telling me there is nothing they can do when I can clearly see the year make and model have had a recall for the exact issue that I am having with this car. …”

NHTSA complaint #10875785, filed 2016-06, 104,000 miles

Mileage when problems were reported

40% of the 35 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 36,000 and 97,000 miles.

6%0–1011%10–2523%25–5014%50–7523%75–10020%100–1503%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (35 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 64,000 miles.

Complaints by year filed

Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.

’056’07’096’11’14’16’18’20
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Crash test ratings

NHTSA's 5-Star Safety Ratings for the 2004 Volvo S40. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.

VersionOverallFrontalSideSide poleRollover
S40 · sedan not rated4 / 5———

Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.

Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.

Fuel economy and running cost

EPA ratings for each 2004 Volvo S40 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).

VersionEngineTransmissionCityHwyComb.Fuel / yr
S40 FWD1.9L 4-cyl5-speed automatic192722$3,750
S40 FWD2.4L 5-cyl5-speed automatic192822$3,750
S40 FWD2.5L 5-cyl5-speed automatic192823$3,550

Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.

Recalls and investigations

Recall details for the 2004 Volvo S40 → · Check a VIN at nhtsa.gov/recalls

Technical service bulletins

TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 235 on record; the latest 10 are shown.

See all 235 bulletins →

Other model years of the Volvo S40

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
2011599,5002—24—Not enough data
2010976,0002—24—Not enough data
20091065,0003—23—Not enough data
20081675,2652—23—Falling
20072557,5002—22Not compared (before 2008)Falling
20065875,0003—22Not compared (before 2008)Falling
20056976,5003—22Not compared (before 2008)Falling
20044864,0006—22Not compared (before 2008)Falling
20031885,1062—22—Falling
20022745,0001—22Not compared (before 2008)Stable
20018467,0002—23Not compared (before 2008)Falling
200012273,4581—21Not compared (before 2008)Falling

All Volvo S40 model years · Best and worst years by complaints

Frequently asked questions

How many NHTSA complaints does the 2004 Volvo S40 have?

NHTSA recorded 48 consumer complaints for the 2004 Volvo S40 as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 Volvo S40 is reported most often?

Brakes is named most often, in 12 complaints (25% of the total), followed by air bags with 11.

Has the 2004 Volvo S40 been recalled?

NHTSA lists 6 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.

What gas mileage does the 2004 Volvo S40 get?

The EPA rates the 2004 Volvo S40 (S40 FWD, 1.9L 4-cyl) at 22 mpg combined, 19 city and 27 highway, with an estimated annual fuel cost of $3,750 at 15,000 miles a year. Other engine and drive versions are rated differently.

At what mileage are problems with the 2004 Volvo S40 reported?

Among the 35 complaints that include a mileage, the median is 64,000 miles and the middle half falls between 36,000 and 97,000 miles; 40% were filed for vehicles with under 50,000 miles.

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. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).

Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.