2006 Volvo S40 Problems

What owners report

Owners of this 2006 Volvo S40 most often describe electrical faults, such as gauges dropping to zero, warning messages, and shutdowns while driving. Water entering through the sunroof drain is another frequent theme, and some owners link it to later electrical problems, while engine stalls and fuel pump failures are also reported. Water-related faults are often described as building over time, while the shutdowns and stalls are described as sudden, and listed mileage ranges from under 1,000 to more than 150,000 miles.

1. 1
   Electrical system

   Gauges, warning messages, and shutdowns while driving

   • 24 complaints (41%)
   • median 73,000 mi at 6.8 yrs old (20 state mileage)
   • filed 2007–2022

   Owners describe gauges dropping to zero, warning lights and messages such as brake or airbag failure appearing, and in some cases the car losing power or shutting down while being driven. Several say the systems came back after the car was turned off and restarted, but the faults kept returning. Some report that the dealer could not find the source of the problem, and another says the instrument panel went dark while the car was moving. Among complaints that list mileage, the range is about 11,500 to 115,000 miles, and several describe the problem happening on highways.

   What to check: Ask for any diagnostic records of gauge, warning, or shutdown complaints, and check that the instrument panel and warning lights behave normally on a test drive.

   2 excerpts from owner complaints in NHTSA records

   “My 2006 Volvo S40 has had numerous and intermittent electrical issues including gauges that go haywire, false airbag failure or brake failure messages, locks that don't engage or disengage and traction control that seems to stick or malfunction. On a few occasions the speedometer and RPM readout go completely dead while I'm going 70 miles per hour on the highway. …”

   NHTSA complaint #10369485, filed 2010-12, 71,000 miles

   “While driving down the road at approximately 50 MPH I noticed my dim ( driver information module) had completely stopped working. I was unable to read my speedometer, RPM, fuel level, and engine temperature while the car was still running . After researching this online, it appears that this seems to be a common problem.”

   NHTSA complaint #10817742, filed 2016-01, 114,000 miles
2. 2
   Engine

   Engine stalls or loses power while driving

   • 19 complaints (33%)
   • median 80,000 mi at 7.9 yrs old (15 state mileage)
   • filed 2008–2022

   Owners describe the engine stalling, cutting out, or losing power while driving, in traffic, or at idle, often with a check engine light on. Some report the car would not restart right away or only after several attempts, and others describe slow acceleration or a delayed start. Some say a dealer or mechanic could not reproduce or fully diagnose the failure, and others say the problem returned after repairs. Among complaints that list mileage, the range is about 57,000 to 156,000 miles, and stalls are described from idle up to about 65 mph.

   What to check: Ask whether any stalling or power loss was reproduced and diagnosed, and review service records for repeat visits for the same symptom.

   2 excerpts from owner complaints in NHTSA records

   “Prior to this incident, my car idled down and pressing the gas did not prevent it from coming to a complete stop. The check engine light illuminated and all of the lights came on to include, warning lights, airbag, stability control, and others including ABS. Fortunately we had just exited the highway to purchase fuel and was in no immediate danger. …”

   NHTSA complaint #10764605, filed 2015-09, 156,185 miles

   “In some occasions car won't start and while driving the car it would shut off unexpectedly causing a dangerous situation. I believe it's the pump electronic module which is already recalled in some cars. According to your recall I have the exact same symptoms but my VIN number is not part of the recall.”

   NHTSA complaint #11378407, filed 2020-12, 108,000 miles
3. 3
   Body and structure

   Water in the cabin, often via the sunroof drain

   • 12 complaints (21%)
   • median 89,500 mi at 8.9 yrs old (8 state mileage, few)
   • filed 2007–2020

   Owners describe water entering the cabin, with carpets and floor areas soaked after rain or a sunroof leak. Several say the sunroof drain was clogged or its channels or hoses had failed, and some link the water to electrical faults such as failed windows, locks, or instrument warnings. Some owners say the dealer cleared the drains or cleaned the floor, and that water returned later, while others report mold or musty odors. Among complaints that list mileage, the range is about 65,000 to 151,000 miles, and some water problems are described after rain.

   What to check: Check the sunroof drain channels and the carpets and floors under both front and rear seats for dampness or musty odor, and ask whether the drains were cleared and the wiring inspected.

   2 excerpts from owner complaints in NHTSA records

   “Water leaked into my vehicle through the sunroof, destroyed the computer and air airbag system. The carpets are soaked with standing water sitting in the body of the front passenger side of the vehicle. I took my vehicle to the dealership and was told the sunroof drainage tubes where clogged. I was then quoted a price for repairs which totaled in excess of $2000.00.”

   NHTSA complaint #10681158, filed 2015-02, 90,000 miles

   “We had been experiencing rain showers on the way to work the Volvo twice had all the lights on the dash board light up but the car did not stall. I was afraid the air bag might deploy. As soon as I got home I had my husband check to see if he could locate the problem. He found was that the carpet was soaked on the drivers side .and the. Wiring running under the carpet was also wet. We have not moved the car and are trying to dry everything. It has also continued to rain off and on. …”

   NHTSA complaint #10706210, filed 2015-04, 151,284 miles
4. 4
   Fuel system

   Fuel pump and fuel pump module failures

   • 10 complaints (17%)
   • median 108,000 mi at 10.0 yrs old (7 state mileage, few)
   • filed 2010–2022

   Owners describe the engine not starting, or shutting off while driving, and in several cases link the problem to the fuel pump or its electronic module. One owner says the dealer found that the fuel pump and pump module needed repair, and that the vehicle was not included in the fuel system recall. Another reports a check engine light and suspects corroded wiring to the fuel pump, with a module replacement suggested. A further complaint describes repeated stalls on an incline that an independent mechanic linked to the fuel pump. Among complaints that list mileage, the range is about 56,000 to 108,000 miles, and some describe trouble starting the engine.

   Recall 08V033000

   What to check: Ask whether the fuel pump and pump electronic module were tested or replaced, and look up the vehicle identification number for any open fuel system recall.

   2 excerpts from owner complaints in NHTSA records

   “I went out to start my car for work and it would not start like it was out of but I have a half tank of gas in it but for some reason it sounds like the fuel pump/module is not working.”

   NHTSA complaint #11322320, filed 2020-04

   “Check engine light came on and has stayed on. Stalled out in traffic, turned the car off and it restarted and I continued. Happens two more times. Initial start up has a delay in the engine turning over. Gas pedal is slow to respond to acceleration. Verified at a garage with code reader. Suspect faulty wiring (corrosion) to fuel pump needing PEM replacement. No warning prior to first incident around 02/2022. I have had the check engine light reset on multiple occasions and each time the light comes back on within 2 days. …”

   NHTSA complaint #11470947, filed 2022-06
5. 5
   Electrical system

   Door locks and power windows failing or intermittent

   • 9 complaints (16%)
   • median 71,000 mi at 5.2 yrs old (7 state mileage, few)
   • filed 2007–2020

   Owners describe door locks that do not engage or disengage, and power windows and locks that work only intermittently. In one case the doors locked automatically with the owner inside, and the wipers started and the lights stopped working at the same time. A driver-side door that would not lock reliably was repaired by the dealer, but a humming noise continued in warm weather. One owner reports that power windows and locks stopped working after water entered the car. Among complaints that list mileage, the range is about 6,000 to 125,000 miles, and several of these problems are described as intermittent.

   What to check: Operate each door lock, power window, and the central locking on a test drive, and ask whether any door lock or window module repairs are on record.

   2 excerpts from owner complaints in NHTSA records

   “Vehicle passenger rear floor flooding continuously. One day the windshield wipers wouldn't turn off and none of the interior electrical equipment would work, no power windows or locks. Drove to Volvo, they stated clogged sunroof drain and that floormat had affected the ECM under the steering column. They cleared drain and cleaned floor for $1k. A year later the front drivers seat floor started flooding. Experienced many electrical problems since. …”

   NHTSA complaint #10672809, filed 2015-01, 125,000 miles

   “Whilst driving, the instruments on the instrument cluster dropped to zero and the warning lights started flashing. After shutting down the car, and then restarting, the fault cleared. Ever since, the electric windows and door locks have worked only intermittently. Volvo diagnosed the problem to the a-pillar connectors, which they said were old, and newer ones had been made. Volvo will not pay for the replacement since the car's warranty has expired. …”

   NHTSA complaint #10453439, filed 2012-03, 86,000 miles

Buying note. Buyers considering this model year may want a pre-purchase inspection that checks the sunroof drains, the carpets and floors for water or mold, and the instrument panel and warning lights during a test drive. Asking for service records of any stalling, fuel pump, or electrical repairs can help show how these problems were handled.

Summary written with AI from a sample of 55 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.