2005 Volvo S40 Volvo S40 2005

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2005 Volvo S40 repairs by problem area

Engine (36%)

Transmission and Drivetrain (9%)

Brakes and Traction Control (5%)

Suspension and Steering (14%)

Electrical and Air Conditioning (24%)

Paint, Rust, Leaks, Rattles, and Trim (4%)

Other (7%)

Chart based on 182 repairs.
See TSBs and recalls for the 2005 Volvo S40.

2005 Volvo S40 repair cost distribution

$2500+ (6%)

$1000 - $2499 (10%)

$500 - $999 (14%)

$100 - $499 (27%)

< $100 (43%)

Worried about potential repair costs? An extended warranty can provide peace of mind.

Chart based on 96 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2005 Volvo S40

Engine not specified

Volvo S40 in Great Britain
Apr 2011 - Sep 2012
May 2012

114700 mi

£2000
4 new shock absorbers 

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2005 Volvo S40 4dr Sedan

turbocharged 218hp 2.5L I5 6-speed manual FWD

Volvo S40 in Texas, United States
Jun 2010 - Jan 2011
Jul 2010

75000 mi

US $1100
A/C was shorting out according to Dealer. A/C would intermittantly not blow cold. Dealer told me the whole unit needed to be repaired. $1100 repair at only 75,000 miles.  
Dec 2010

81000 mi

US $2350
2 problems. Seats started cracking with 82k miles. this is a manufacturer defect. deal paid half. Owner paid $650. $880 to repair CD Deck error. I did not replace. alternator needed to be replaced. $880. did not repalce. traded car for a new Nissan 
Volvo S40 in Ohio, United States
Apr 2008 - Apr 2013
Jul 2008

59000 mi

US $110
6 CD changer center spindle broke, subsequently would not eject CD's, replaced entire CD changer with used unit. 
Jun 2009

69000 mi

US $130
Replace front sway bar end links. Front right went bad. 
Aug 2009

70000 mi

US $12
Check valve on window washer came apart and needed replaced. 
Jun 2010

77000 mi
Cracked PCV Box 
Aug 2010

77600 mi
Parking brake stuck in the on position. Corrosion built up at the end of the cable housing on the left rear wheel. Extensive lubrication and cleaning of the cable corrected the problem at this time. 
Dec 2010

79000 mi

US $742
Replaced right side wheel bearings both front and back, both were bad, the front with excessive noise and flat spot and back had significant play. 
Volvo S40 in Alabama, United States
Apr 2010 - Aug 2011
May 2010

49000 mi

US $398
Fuel pressure sensor replaced 
Sep 2010

54000 mi

US $125
Software patch installed to fix AC sometimes blowing hot and cold at same time. Problem has happened twice. 
Aug 2011

60000 mi

US $1214
Air conditioner compressor replaced.  Also leak onto carpet caused by AC drain hosed fixed. 
Volvo S40 in Texas, United States
Jan 2011 - Oct 2011
Feb 2011

98000 mi

US $700
Cracked diapragm in the breather box. Breather box replaced. 
Jun 2011

105000 mi

US $200
AC would work fine for about 15-20 minutes of driving, then start to pull in hot air from outside. Compressor clutch was repaired. 

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2005 Volvo S40 4dr Sedan

turbocharged 218hp 2.5L I5 6-speed manual AWD

Volvo S40 in Wisconsin, United States
Jun 2015 - Jun 2018
Jul 2015

149500 mi

US $80
Replace engine torque mount. Shim AC compressor. 
Jun 2016

160000 mi

US $100
Replace: both rear differential seals, driver rear axle (torn boot), rear wheel bearing. Replace failed alternator. Replace passenger front wheel bearing. 
Sep 2016

164000 mi

US $220
Replace PCV oil trap. Replace AWD controller and pressure sensor. 
Jan 2018

169000 mi

US $1200
Replace clutch, flywheel, slave and angle gear collar. Replace fuel pump 
Volvo S40 in Kansas, United States
Oct 2013 - Nov 2013
Oct 2013

116000 mi

US $987
Alternator went out. Replaced with battery. Afterwards received deck error from CD player. 
Nov 2013

116000 mi

US $51
Harmonic Balance nut worked loose, caused belts to be thrown, quick fix but could of blown my engine. 
Volvo S40 in British Columbia, Canada
Jun 2013 - Jun 2013
Jun 2013 anti skid warning needing service. Goes on and off randomly. alarm would go off in the middle of the night, over and over! 2 wheel bearings failing at the same time. ac belt and drive belt because of a chirp coming from the engine. 
Volvo S40 in Florida, United States
Feb 2007 - Dec 2016
Apr 2009

58000 mi

US $219
Intermittent Check Engine Light 
Jun 2011

89000 mi
AC Compressor Clutch replaced. 
Mar 2013

103000 mi

US $700
Battery was leaking, corroded battery and battery cables were replaced. 
Aug 2014

111000 mi

US $1400
Alternator failed, replaced Alternator failed, killed battery Cam seal oil leak 
May 2015

117400 mi

US $400
Brake sensor replaced, reverse lights were intermittent. Engine mount damaged 
Jun 2016

127000 mi

US $350
Cracked Coolant Reservoir 
Nov 2016

128000 mi

US $300
InnerCV boot leaking 
Volvo S40 in Virginia, United States
Jul 2009 - Nov 2014
Sep 2009

38000 mi
TSB 205 - PCV Vent box. Dealer did not reconnect dipstick tube to engine in Sep service #1. Dipstick tube fell out of oil pan. When I brought it in, they pop-riveted it back on! This time they replaced the PCV assembly and used a bolt to secure the dipstick tube. After 3 visits! 
Sep 2010

47000 mi

US $950
O2 sensor check engine light, dealer replaced battery harness and O2 sensor. 
Nov 2014

89000 mi

US $6700
Timing belt tensioner failed 

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2005 Volvo S40 4dr Sedan

turbocharged 218hp 2.5L I5 5-speed shiftable automatic FWD

Volvo S40 in Switzerland
Jun 2006 - Mar 2010
Jun 2006

21700 mi
cd charger 
Jan 2007

24800 mi
climate control reset 
Volvo S40 in Texas, United States
Apr 2010 - Dec 2012
May 2010

45500 mi
Replaced windshield wiper washers Replaced windshield wiper washers 
Aug 2011

59000 mi

US $125
Coolant reservoir developed a crack and all coolant leaked out 
Sep 2011

60000 mi

US $86
When driving, the car gave bucking sensation so severe, it felt like I had been rear-ended by another car. After this, I received the message "Transmission Service Urgent" and odd transmission behavior. Dealer performed TCM software upgrade 
Aug 2012

71900 mi

US $45
The auto transmission felt like it slipped a gear and message appeared in Trip Computer saying 'Transmission Service Urgent'. Dealer said they were not able to replicate, but performed a software update. This seemed to fix issue. 
Volvo S40 in Texas, United States
Feb 2005 - Mar 2010
Jul 2005

6000 mi
Radio random lockups were repaired under warranty 
Aug 2006

24000 mi
Some vibrations at low and high speeds were repaired under warranty with software update for the transmission and replacement of an axle. Axle could have been damaged from pot hole from hell. All fixed under warranty. 
Dec 2008

67000 mi

US $90
Clogged PCV caused a squealing noise.  I replaced the oil filter housing. 
Mar 2009

71000 mi
Airbag sensor was not working on the passenger seat. Dealer reset it and is working fine. 
Volvo S40 in New York, United States
Oct 2009 - Jun 2015
May 2011

41000 mi

US $160
Trunk lock would not disengage, replaced trunk lock assembly. 
Aug 2012

42000 mi

US $400
fuel pressure sensor failure 

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2005 Volvo S40 4dr Sedan

turbocharged 218hp 2.5L I5 5-speed shiftable automatic AWD

Volvo S40 in Ontario, Canada
Apr 2007 - Mar 2010
Jan 2007

13026 mi
CD Player Replaced under Warranty 
May 2007

18207 mi
L Front Wheel Bearing Replaced (Warranty) 
May 2009

37200 mi
Front Right Wheel Bearing Worn - Front Wheel Hub Assembly replaced. 
Sep 2009

45880 mi
Oil trap box (housing oil filter is attached to) - plugged 
Volvo S40 in Quebec, Canada
Nov 2017 - Jan 2018
Dec 2017

88660 mi

C $75
Hole in flex pipe, flex pipe was replaced with a new OEM grade unit Rear sway bar end links replaced with new OEM grade links 

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2005 Volvo S40 4dr Sedan

168-horsepower 2.4L I5 5-speed shiftable automatic FWD

Volvo S40 in Illinois, United States
Jul 2010 - May 2011
Mar 2011

61000 mi

US $125
Wipers could not be turned off, gas gauge went to zero (after just filling the tank), SRS airbag light on, trunk lid open light on. Found loose/faulty electrical wire. 
Volvo S40 in Alabama, United States
Sep 2015 - Jun 2016
Sep 2015

138000 mi

US $1200
transmission needed to be replaced 
Jun 2016

136000 mi

US $3500
some belt broke and tore my air conditioner lines up. if i kept driving it it would have totaled the car 
Volvo S40 in Texas, United States
Dec 2012 - Jan 2013
Jan 2013 Software update 
Volvo S40 in Pennsylvania, United States
Apr 2015 - Mar 2016
Jun 2015

87000 mi

US $2000
Air conditioning cycles off after 10-15minutes Growling noise from rear of car while driving. Both rear wheel bearings worn. Both rear hubs replaced. 
Mar 2016

89000 mi
Multiple warning lights illuminated, wipers switched on uncommanded, transmission reverted to "limp" mode. No parts replaced...got rid of car instead. 
Volvo S40 in Indiana, United States
Feb 2014 - Aug 2014
Jun 2014

124000 mi
Right wheel bearing needed replaced. Had to grind off the existing one as it was rusted throughout. 
Aug 2014

124000 mi

US $750
Alternator had to be replaced. 
Volvo S40 in New Hampshire, United States
Jul 2012 - Jul 2022
Feb 2013

96300 mi
sunroof drain was disconnected which caused the floors to fill with water. I have reconnected the drain and removed the standing water though the carpets and insulation under are still quite wet. I see from my internet search this common 
Volvo S40 in Ohio, United States
Feb 2007 - Apr 2010
Apr 2009

40000 mi
I needed a software upgrade (ECM Gasoline Up) and the PCV hose from the oil trap to the head failed. 
Apr 2010

53000 mi

US $100
Failed brake sensor. Parts ordered and car repaired in 2 business days. Happy with process. Total cost (including $100 deductible) was $270. 
Volvo S40 in Virginia, United States
May 2007 - Jan 2009
Aug 2007

28000 mi
Check engine light came on and air conditioner started blowing HOT air on driver's side only 

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2005 Volvo S40 4dr Sedan

168-horsepower 2.4L I5 5-speed manual FWD

Volvo S40 in Ontario, Canada
Mar 2013 - Jan 2014
Sep 2013

81220 mi

C $248
Squeaky clutch pedal with slow return. clutch spring was replaced. 
Jan 2014

C $350
Right rear wheel bearing was noisy and had to be replaced. Right lower arm clunky and the left rear shock absorber was shot Manual transmission hard to use in winter. Noisy clutch release bearing, AC compressor clutch burnt. Squeaky accessory drive belt possibly due to missing engine splash guard. Engine splash guard came out. Decided not to replace as I was selling the car. 
Volvo S40 in Illinois, United States
Nov 2010 - Jun 2018
Mar 2011

79000 mi

US $350
Check engine light on. When tested, had error code ECM-2600. Replaced faulty fuel pressure sensor. 
Jun 2011

80000 mi

US $3500
No AC. Replaced condenser. $1700. Replaced shocks, discovered problem at tire shop, $1800. 
Aug 2012

90900 mi

US $3095
Clutch was slipping. Diagnosed as failed clutch. Replaced the clutch, flywheel, and throw out bearings. Cracked breather hose. Replaced hose and the intake seals. 
Aug 2014

101000 mi

US $3072
Parking brake doesn't hold intermittently. Parking brake cables were binding. Replaced cables and wire box. Excessive vibration, rough ride, appears to be coming from front end. Left front axle was vibrating and inner boot torn. Replaced left front axle shaft. Left front spring broken, struts leaking and strut bearings binding on turns, bump rubber damaged. Replaced springs and struts with related bearings and bump rubbers. 
Oct 2016

113500 mi

US $900
Front end noise, worse on left side, caused by worn wheel bearings. Replaced front left & right wheel bearings. Right motor mount leaking fluid. Replaced. Rear passenger taillight out. Replaced. 
Apr 2017

120000 mi

US $42
Replaced right headlight. 
Nov 2017

127000 mi

US $1971
Intake manifold gasket, oil separator and gasket, spark plugs, air flow sensor. Camshaft and crankshaft seals. Right front axle. 
Volvo S40 in Ontario, Canada
May 2011 - Dec 2016
Jun 2012

104160 mi

C $300
Battery died and had to be replaced. 
Jun 2014

121520 mi

C $300
CV boot front strut 
Volvo S40 in Pennsylvania, United States
Dec 2016 - Mar 2017
Jan 2017 Clutch spring failure. Mechanic could not physically replace the spring. 
Feb 2017

129000 mi

US $500
Emissions system check engine light. Throttle cleaned to fix problem in short term. Diagnosis is catalytic converter and will likely need replacing at a cost of $500-$700. 
Volvo S40 in Alberta, Canada
Feb 2010 - Aug 2014
Aug 2014

48980 mi

C $1200
Front shocks need replacing  
Volvo S40 in Spain
Nov 2007 - Jun 2011
Nov 2008

39358 mi
Loose cable on fuel pump. Loose cable on fuel pump 
Jun 2009

46500 mi
Alternator. 
Volvo S40 in Pennsylvania, United States
Sep 2006 - Jan 2017
Jan 2006

25000 mi
Engine light came on - needed to have carbon deposits removed from intake manifold. 
Nov 2009

41000 mi

US $50
The windshield wiper check valve had failed 
Mar 2010

43000 mi

US $660
Water was found behind the passenger seat. It was diagnosed to be a plugged sunroof drain pipe backflowing into the car. 
Nov 2011

51000 mi
The dealer removed the interior carpets and insulation, dried the vehicle, and cleared the sunroof drainage tubes that were blocked causing a leak 
Apr 2012

55000 mi

US $550
one motor mount was degraded and required replacement. This was detected during a normal service interval. 
Nov 2012

59400 mi

US $960
Replaced worn lower control arm 
May 2013

64100 mi

US $175
I experience periodic blockage of the sunroof drainage tubes. Part of this service interval addressed this issue. 
Aug 2015

82600 mi

US $732
Headlining delaminating - replaced entire headlining. 
Jan 2016

77800 mi

US $140
Symptom was power steering pump stopped working. Diagnostic codes and battery load test indicated failing battery. 
Nov 2016

92900 mi

US $4200
CV boots replace engine mount strut shocks 

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2005 Volvo S40 4dr Sedan

143-horsepower 2.0L I4 5-speed manual FWD

Volvo S40 in Alberta, Canada
Aug 2015 - Jan 2022
Mar 2016

64480 mi
Replaced front shocks. One was leaking and the other was soft. Also timing belt change. 

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2005 Volvo S40 4dr Sedan

123-horsepower 1.8L I4 5-speed manual FWD

Volvo S40 in Ireland
Jun 2009 - May 2010
Mar 2010

55800 mi

€600
Replaced alternator. When sold the 'brake failure, engine stop' message still came up from time to time. Shop couldn't diagnose even with code. When it happened indicators and wipers wouldn't work or wouldn't turn off. Or the car wouldn't start for up to three days. 

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2005 Volvo S40 4-door

turbocharged 5-cylinder automatic 2WD

Volvo S40 in Virginia, United States
Feb 2007 - Apr 2016

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2005 Volvo S40 4-door

5-cylinder automatic 2WD

Volvo S40 in Florida, United States
Dec 2007 - Jul 2008
Jan 2008

31000 mi
There is a rattle noise coming from the engine bay at idle. Originally thought to be a loose hose, dealer tightened hose and the noise still persists. Replaced faulty passenger airbag sensor. 
Mar 2008

32000 mi
I was driving when a "Warning, low brake level fluid, stop immediately" light came on. I pulled over and had Volvo come tow me to the dealer. I just had my 30,000 mile service done 3 months ago, so dealer inspected the brake fluid container and ... 
May 2008

36000 mi
Splash guard underneath engine disconnected from all 5 front clips falling to the ground. Was still connected at the back. Couldn't drive car because any bump or object in the road would rip off splash guard. Towed to dealer by roadside asst. and fixed. 

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2004.5 Volvo S40

Engine not specified

Volvo S40 in Ontario, Canada
Nov 2014 - Apr 2015
Mar 2015

133920 mi
Car would start, then shut off. Car would not start and run without immediately revving the car almost to max after ignition. 
Apr 2015

133920 mi

C $350
Had to replace both drive shafts. 
Volvo S40 in Georgia, United States
Mar 2012 - Apr 2012
Apr 2012

83000 mi

US $4300
Vechicle overheated and they originally thought it needed the head gasket replaced but it turned out that it could not be repaired and needed a whole new engine. Mechanic said that the engine was rare but i don't really believe that. 

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2004.5 Volvo S40 4dr Sedan

turbocharged 218hp 2.5L I5 6-speed manual FWD

Volvo S40 in Michigan, United States
Aug 2010 - Jun 2013
Sep 2010

117000 mi

US $650
Vehicle would not recognize key. Had to have new switch installed. Check engine light has come on. Again. Some times it goes away, but returns later. Probably a sensor is going. Just going to live with it. Just another repair cost to this vehicle. 

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2004.5 Volvo S40 4dr Sedan

turbocharged 218hp 2.5L I5 5-speed shiftable automatic FWD

Volvo S40 in North Carolina, United States
- Aug 2006
Aug 2006

26000 mi
Car was rattling over bumps. They said the cage that protects the gas tank was hanging down. It was replaced. 
Volvo S40 in New Jersey, United States
Oct 2008 - Dec 2015
Nov 2008

91000 mi
Dealer cleaned out drain tubes because they were clogged and was allowing water into floor of back seat floor. 
Apr 2009

105000 mi

US $100
ABS light came on; problem traced to faulty ABS wheel speed sensor. Dealer did not have in stock so customer ordered it elsewhere and installed it on their own. Installed wheel speed sensor. 
Dec 2009

132000 mi

US $175
Car went in to replace timing belt. Successfully changed, no problems. Water pump replaced at the same time that the timing belt was changed as preventative maintenance. Replaced a torn engine mount....fixed successfully the first time. 
Jul 2010

150000 mi

US $600
Replaced front struts and bearings 
Sep 2010

156000 mi

US $528
A wheel hub was noisy and replaced successfully. 
Mar 2011

177000 mi

US $600
Another wheel hub replaced Starter replaced 
Apr 2011

178000 mi

US $800
Replaced starter. Replaced both lower control arms and passenger side axle. 
Dec 2011

201000 mi

US $284
replaced driver's door module that controls door locks and window operation 
Apr 2012

216500 mi

US $330
Turbo Control Valve replaced 
Jun 2012

224000 mi

US $350
Replaced fuel pressure sensor 
Jul 2012

225200 mi

US $420
replace compressor and clutch 
Jan 2013

242000 mi

US $400
Replaced heater core 
May 2013

246000 mi

US $159
Replaced rear shocks. 
Jan 2014

210500 mi

US $75
Engine coil on cylinder 1 failed and caused check engine light to come on. 
Jun 2015

272000 mi

US $700
Coolant hoses split and thermostat housing was leaking 
Volvo S40 in Georgia, United States
Feb 2010 - Jun 2011
Mar 2010

66000 mi

US $230
AC compressor not turning on, no cold air. 

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2004.5 Volvo S40 4dr Sedan

168-horsepower 2.4L I5 5-speed shiftable automatic FWD

Volvo S40 in Texas, United States
Oct 2009 - Mar 2013
Mar 2013 Torn CV axle boot. 
Volvo S40 in California, United States
Aug 2007 - May 2015
Oct 2007

38000 mi
Rolling noise from front of car, springing noise from seats and suspension 
Mar 2008

48000 mi
Clicking noise from front part of car, suspension ticking, electrical sounds from front right of car, scratched panel, dealer dented car had to get touched up. 
Oct 2008

65000 mi

US $140
Mod went wrong. 
Jan 2009

68000 mi
AC didnt blow cold after a recharge; new compressor. 
Mar 2010

96000 mi
cd player doesn't eject. ignition went out. 
Jun 2012

140000 mi

US $1800
replaced CEM (central electronic module) 
Aug 2013

161000 mi

US $150
Known problem Pcv 
Feb 2014

165000 mi

US $600
Head Gasket 
Jan 2015

166000 mi
Head gasket failure. 
Volvo S40 in Oregon, United States
Jan 2016 - Sep 2016
Jun 2016

70000 mi

US $775
Headliner had pretty much all fallen down. On the front door panels, some areas of the fabric cover had come unglued. 

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2004.5 Volvo S40 4dr Sedan

123-horsepower 1.8L I4 5-speed manual FWD

Volvo S40 in Great Britain
Apr 2010 - Oct 2011
Jun 2010

62000 mi

£700
Check engine light illuminated. Fault located to throttle module. Throttle module replaced, fault still present. Next stage is replace wiring harness. Alternator also packed up whilst in the garage. 
Oct 2011

76000 mi

£300
Probably coil packs Throttle body communication. Same fault as last year. Minimum £500 repair so car was sold as faulty. 

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2004.5 Volvo S40 4-door

turbocharged 5-cylinder automatic 2WD

Volvo in Puerto Rico
Feb 2007 - Jul 2009
Mar 2007

35000 mi
Vacuum pump defect 
May 2007

36000 mi
Same vacuum pump 
Jun 2007

38000 mi
The vacuum pump of the brake system was changed. Driver side vent visor is damaged. And also driver door seal is broken. 
Mar 2008

43000 mi
New weather strip placed. Xenon lights needed leveling. 
May 2008

46000 mi

US $400
Need to replace bad struts...... 
Jul 2008

47000 mi
Fuel pump module needed to be replaced. One oxygen sensor replaced. 
Oct 2008

50000 mi
An hydraulic engine mount was defective 
Jan 2009

52000 mi
Engine mount replaced. 

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2005 Volvo S40 Repair Histories

See our lemon odds and nada odds page to see vehicles with no repairs or vehicles with more than three repairs. To see how frequently 2005 Volvo S40 problems occur, check out our car reliability stats.