Volvo S60 Volvo S60

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Volvo S60 repairs by problem area

Engine (28%)

Transmission and Drivetrain (10%)

Brakes and Traction Control (8%)

Suspension and Steering (22%)

Electrical and Air Conditioning (20%)

Paint, Rust, Leaks, Rattles, and Trim (6%)

Other (6%)

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Chart based on 1414 repairs.
See TSBs and recalls for the Volvo S60.

Volvo S60 transmission repair cost distribution

$2500+ (10%)

$1000 - $2499 (14%)

$500 - $999 (16%)

$100 - $499 (43%)

< $100 (16%)

Chart based on 143 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2013 Volvo S60 4dr Sedan

turbocharged 250hp 2.5L I5 6-speed shiftable automatic AWD

5000 mi Lurching occurs when going from Park to Drive and releasing the brake pedal. 
28300 mi all wheel drive system service bulletin 

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2012 Volvo S60 4dr Sedan

turbocharged 300hp 3.0L I6 6-speed shiftable automatic AWD

14500 mi AWD deactivated light came on. Reset it itself automatically. No codes found by dealer. 

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2012 Volvo S60 4dr Sedan

turbocharged 250hp 2.5L I5 6-speed shiftable automatic FWD

7500 mi Rough downshift from 5th to 4th gear. Transmission replaced. 
15000 mi Transmission started downshifting abruptley at throttle liftoff around 25 mph. Manufactuer computer debug done. Is much better but happens occassionally. 
8500 mi Rough down shifting at 30MPH 
30000 mi Rough shifting. 
12000 mi rough downshift (performed transmission control module software upgrade RTJ26840) 
22000 mi Rattling and Vibration coming from engine upon moderate acceleration and coasting. Will occur whether the vehicle is in gear or in park. Sound does not occur when in sport mode. Still experiencing vibration and rattling sounds 
4000 mi Rough downshifts, especially with letting off the throttle. 
7500 mi Very rough, very occasional downshifts into 1st gear in 'sport' mode. Almost feels like the car has hit a curb! Dealer cannot reproduce and no codes are set. No noise and no trans. 2 software updates have helped slightly. 
30000 mi Problem: Car exhibits a harsh 2-1 downshift in stop and go traffic. Occasionally it made a mechanical clunk during the harsh shift. Dealer flashed new software to correct harsh downshifts. 
60000 mi Periodically the transmission begins making an low pitched moaning sound. Usually but not always when the car first is operating. Dealer Tech could not duplicate. 

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2012 Volvo S60 4-door

turbocharged 4-cylinder automated manual 2WD

5980 mi There where loud sounds when going from 1 st gear to 2nd gear and downwards too. Plus a shudder and a shake when you put the car back into neutral. They said some rubber thing needs replacement, and they have ordered it for me. 
12400 mi

﷼1350
Rough down shifts and lots of noise from the transmission. Car surges forward when I am about to stop. 

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2007 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 6-speed shiftable automatic AWD

85000 mi

US $170
Driver's front side made a clunk noise during gentle on/off throttle, and on rough roads at low speed. Inspection showed axle bolt behind the driver's side front wheel cap had come loose. Bolt was re-inserted and Loctite was added. 
29000 mi Transmission shifting roughly. Could not replicate. 
95000 mi

US $25
Clicking in front axle. Purchase new axle bolt with rubber bushing and replaced. 10 minute job. Click is gone. Use one for xc90 not original. 
103000 mi hard shift 2-3rd gear. 
113000 mi

US $750
repalced angle gear and sensor 

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2006.5 Volvo S60 4dr Sedan

turbocharged 182hp 2.4L I5 Diesel 6-speed manual FWD

102000 mi

£1024
Clutch slave cylinder leaking. Should have been changed when the 1st bad clutch was fitted (labour costs dictate replacement at time of clutch change - standard respectable garage practice). 

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2006 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 6-speed shiftable automatic AWD

24000 mi Had auto trans valve body replaced by dealer under warranty due to harsh downshifting.  
28000 mi revised valve body replacement 
49600 mi Valve body Angle gear (AWD) 

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2006 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 6-speed manual AWD

39000 mi Had to visit a second dealer to get AWD system covered under warranty. 
57000 mi Clutch position sensor failed. Also, clutch pedal springs fell off the car. 
68000 mi The spline sleeve/collar and angle gear of the AWD system failed with a loud metallic BANG and had to be replaced. This is a very common failure for modern Volvo AWD systems and as such was easy for myself and the dealer to diagnose. 
38000 mi AWD began slipping on initial takeoff under full throttle. Initial diagnosis was nothing wrong. AWD then failed 1 year later. Collar was broken and stuck to shaft, which warranted a new tranmission. The angle gear was also replaced. 

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2006 Volvo S60 4dr Sedan

turbocharged 257hp 2.4L I5 5-speed shiftable automatic FWD

89280 mi The sensor light was triggered. (transmission service required urgent) 

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2006 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed shiftable automatic AWD

61380 mi

C $1300
Haldex Differential Electronic Module 

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2006 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic FWD

139000 mi

US $400
Replaced right and left Axles/CV joints due to torn boots and noisy CV joints. $110. 

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2006 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic AWD

101000 mi

US $50
AWD went out 

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2005 Volvo S60

Engine not specified

124000 mi

R 4500
Geartronic valve bodies suspect, replaced transmission with remanufactured unit. 
61000 mi

US $2100
Clutch Cylinder Failure About 500 miles later the whole assembly failed thus the AWD was dead and in Front Wheel Drive mode only, this would be okay except it would have severe wheel hop, spin and pull. Towed to dealer and replaced. 
78000 mi

US $560
Both axles had to be replaced.  

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2005 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 6-speed manual AWD

19000 mi Angle gear slack and clicking was fixed with loctite 
28000 mi Leaking Angle Gear needed to be resealed. Expensive! 
133500 mi

US $258
Replace upper engine mount 
63000 mi

US $400
Transmission seals were replaced due to a small trans oil leak where the transmission mates with the angle (bevel) gear of the car.  
76000 mi

US $800
Had oil leak @ rear differential. Fix is to reseal. Dealer resealed rear differential. 

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2005 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 5-speed shiftable automatic AWD

78000 mi

US $375
Left front wheel bearing needed to be replaced. 
53000 mi

US $245
Axle Ping issue fixed with Volvo XC90 axle bolts. 
33000 mi Leaking Angle Gear. 
107000 mi

US $500
Front Passenger Axle went out- RR axle 

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2005 Volvo S60 4dr Sedan

turbocharged 257hp 2.4L I5 5-speed shiftable automatic FWD

106300 mi

US $1400
CV boot 

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2005 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed shiftable automatic FWD

50000 mi Vibration reported in front end. Dealer replaced axles. 

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2005 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic AWD

70000 mi

US $560
replaced worn transmission torque rod, $300 
80000 mi

US $680
Replaced PNP Switch Replaced Control Unit Module on AWD 
51142 mi

US $77
no awd - replace oil pump on haldex aoc system 

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2005 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed automatic FWD

103000 mi

US $680
Replaced torn CV joint left front wheel 

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2004 Volvo S60

Engine not specified

116000 mi

US $3600
Its Bevel gear makes loud sound & replacing cost $2000. I sold the car back to dealer from whom I purchased. Really very bad experience with Volvo. 

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2004 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 6-speed manual AWD

65000 mi Sold car because a close friend who has a Volvo repair shop told me that the clutches tend to fail, and replacing them costs over $3,000. Clutch failed two months later. 
120000 mi

US $1300
Clutch needed to be replaced. The slave cylinder failed, causing brake fluid to leak onto the disk. The disk broke in half when it deteriorated from the fluid. 
79700 mi

US $2500
I repaired and maintained multiple things. Front left cv axle, 
83000 mi

US $900
Also had to replace both front left and front right cv axles. 
99000 mi

US $2600
Clutch slave cylinder failed. Replaced slave cylinder, clutch and pressure plate, angle gear collar sleeve, misc seals. Replaced rear main seal (no additional labor) 
122000 mi

US $1200
Replaced clutch disc, pressure plate, flywheel, slave cylinder, angle gear coupling, resealed angle gear. Angle gear input spline was bad but since I did not have another unit, I reinstalled it. Installed a rebuilt angle gear assembly. Input spline shaft on existing was severely worn. 
111600 mi

C $600
Angle gear sleeve repair 
73000 mi

US $800
Repair/replace leaking angle gear seal 
2000 mi Buzzing shifter worked on under warranty and a factory noted update. Still buzzed in 3rd gear. 
37500 mi

US $4000
Clutch sleeve cylinder and multiple components failed all the way up to flywheel. Brake fluid was noted to be leaking a few months earlier. 
39000 mi

US $250
Apparently from last repair one bolt from the strut mount was not replaced and therefore strut broke. Had to be replaced. 
43400 mi Replace ring gear, hesitation on acceleration and replace heater/AC blower 
57000 mi Buzzing sound in 5th gear; Tech service bulletin work performed. 
40000 mi shifter cables were replaced because there was excessive vibration in the shifter when driving in 5th gear. 
62000 mi

US $1100
Slave/Throw out started to squeal, it was on its way out. While transmission was out, I replaced everything except the dual mass flywheel, I had it cut. Should I just have repalced the slave (Control Cylandar) and its Air Vent Tube, $700 
82000 mi

US $2500
Clutch slave cylinder failure. Unable to engage the clutch, drive the car. Sold to the local Volvo expert for $2500 less than fair value if the car was in good working order. I would not have sold the car except I now have company car. 

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2004 Volvo S60 4dr Sedan

turbocharged 300hp 2.5L I5 5-speed shiftable automatic AWD

65000 mi

US $625
Angle gear left side seal leaking, replaced seals. 
226300 mi

C $5600
replaced both front axels..right side was failing so I did both.  
83000 mi

US $4000
Three days after engine replaced in December (tensioner idler went causing timing to slip) transmission also replaced. Transmission pump went. 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed shiftable automatic FWD

112840 mi Shifting problems when sold, transmission going. 
169300 mi

US $6500
Replace Transmission 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed shiftable automatic AWD

104000 mi

US $950
Something was wrong with the bevel gear and it needed to be repaired or the mechanic said it would lead to major damage. 
138700 mi

US $3000
Bevel gear was replaced after failure 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic FWD

35000 mi

US $79
Transmission/turbo still "flaring" between 2nd and 3rd gear around 40 mph. The shop said it may be transmission related but he couldn't reproduce it during his test drive. 
105180 mi

C $500
replaced front CV axles (both sides) 

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2004 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic AWD

95480 mi

C $4400
Angle gear need to be replaced, leaking.rntransmission also leaking, seal need to be replace too. 

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2004 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed automatic FWD

254000 mi

£300
Front left driveshaft replaced 
75000 mi

US $240
Left front cv boot torn, replaced cv drive shaft 
117000 mi

US $430
cv boot cracked 
124000 mi

US $164
left front cv boot split open, replaced complete cv drive shaft 

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2003 Volvo S60

turbocharged 5-cylinder diesel manual 2WD

49600 mi

€2500
Clutch replacement. Mechanical failure. 

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2003 Volvo S60 4dr Sedan

turbocharged 208hp 2.5L I5 5-speed automatic AWD

95000 mi

US $600
slight trany slip so did a full 12 qt. trans fluid flush. 

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2003 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 5-speed automatic FWD

148000 mi

US $375
trans needed B4 cylindar updated and computer reprogram. 
158300 mi Trans won't go into gear after solenoid problem diagnosed. Cost to replace used is $1700. B4 cyl was replaced no effect. 

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2003 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed manual FWD

103000 mi

US $700
Replace right front axle. Mechanic didn't spline everything together correctly. Had to take back. Thought left one went bad but that didn't work, put old left one back in and then realize right one wasn't splined together correctly... 

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2003 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed automatic FWD

57970 mi

R 140
Replaced broken shift knob with new knob from dealer serviced Transmssion, replaced fluid 2X seviced power steering system, replaced fluid 
103000 mi

US $465
Car would not shift. got transmission fluid overheating message and car went into failsafe mode. transmission had to be replaced 
209000 mi

US $450
Replace both passenger and driver CV axles. 
126000 mi

US $1500
also had a boot replaced. 

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2002 Volvo S60 4dr Sedan

turbocharged 247hp 2.3L I5 5-speed shiftable automatic FWD

125000 mi

US $252
Replaced cv joint boots, right side. 
149000 mi

US $787
replaced damaged CV boot on right front axle 
156000 mi

US $120
Check engine light illuminated and "Transmission Service Required" message appeared. Software update/upgrade was performed. Fluid level was slightly low, was filled to correct level. Fluid quality was checked and found O.K. 
157000 mi Check engine light re-illuinated and repeat of transmission service required message. Dealer determined transmission solenoids going bad and recommended transmission replacement ($5,000). Car currently driveable, no telling how long before it isn't. 
115320 mi

$30
Problem with shift flares and alarms with trans. remove solenoids, take apart and clean debris assemble and replace end cap. Refit to trans 

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2002 Volvo S60 4dr Sedan

turbocharged 247hp 2.3L I5 5-speed manual FWD

110000 mi

US $2000
Slave Cylinder failed at 109,000 miles. Clutch, slave cylinder, throwout bearing replaced. Flywheel resurfaced. 

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2002 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 5-speed shiftable automatic FWD

140000 mi

US $48500
Needed automatic transmission replaced. 

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2002 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 5-speed shiftable automatic AWD

168640 mi AWD system has stopped functioning no drive to rear wheels 
194680 mi

C $397
AWD Haldex System no power to back wheels 
76260 mi Starting 110k, would not shift smoothly to 4th and 5th gear. the est. repair cost by a trust worthy independent mechanic was $2,8000CAD. 
76880 mi

C $3300
Done a transmission overhaul to repair the problem shifting into 4th gear. 3,300 later, now the entire car kicks violently shifting when slowing down to turn and then accelerating halfway through the turn. 

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2002 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 5-speed automatic FWD

188700 mi

US $3214
Out right axle boots were torn and replaced, as were the inner and outer CV boots 

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2002 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed automatic FWD

125000 mi Heard noise in front end upon turning. Was told it may be cv joint or axle. was asked to come back but have not done so yet. 
129000 mi

US $1733
Replaced power steering cable, right axle,& bushings. So the axle was the problem with the bumping in front end. (my past mechanics are idiots or just lazy) 1000 dollars in parts alone! 
111000 mi

US $850
while inspecting they found left frt. CV boots bad, so replaced and repacked 
82000 mi

US $600
Axle Replacement 
105000 mi

US $200
Transmision Flush 
104000 mi

US $270
minor transmission leak from axle seals. also passenger axle had a dislocated joint. replaced axle and both seals. 

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2002 Volvo S60 4-door

turbocharged 5-cylinder diesel manual 2WD

76000 mi The drivers side front driveshaft broke, This was due to collapsed ball joints in both of the CV Joints in that driveshaft. 

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2001 Volvo S60 4dr Sedan

turbocharged 247hp 2.3L I5 5-speed shiftable automatic FWD

33260 mi

$4680
Car could not change gears. Transmission replaced.  
104160 mi

$4000
Transmission failed and replaced. Later replaced two more times under warranty. 
114080 mi

$875
Trans fluid contaminated because of broken breather valve. Drained and refilled 4 times. Breather valve was replaced. 

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2001 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 5-speed shiftable automatic FWD

89000 mi

US $175
INNER CV JOINTS 'LOOSE' CAUSING VIBRATION AT ALL SPEEDS WHILE ONLY UNDER LOAD [GIVING IT GAS];COASTING/OFF GAS PEDAL NO VIBRATION... REPLACED BOTH JUST IN CASE [PSSGR SIDE MOST PLAY]. 
90300 mi trans clutch error code; software update... 

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2001 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 5-speed automatic FWD

110000 mi

US $3000
Transmission overhauled. Removed and rebuilt by myself after much study. Spent over $1800 on parts and another $400 on machine work.  
174000 mi

US $272
Full transmission flush required after experiencing transmission slips. Check engine light came on, and "transmission svc. req." msg appeared. Previous flush was >53K miles. Flush fixed problem. 
189000 mi Transmission needed to be replaced, and would have cost more than the car is worth. Decided to register it as non-operational. 

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2001 Volvo S60 4dr Sedan

168-horsepower 2.4L I5 5-speed manual FWD

157300 mi

US $3200
rebuild of transmission 
166000 mi

US $330
cracked cv boot 
184000 mi tranmission failing, traded car in. 
117800 mi

C $1500
Clutch replacement - disc, pressure plate, release bearing, slave cylinder, rear main seal 
120940 mi

C $300
Noise from rf cv joint - replaced axle shaft with aftermarket part 
124620 mi

C $160
replaced left side axle shaft 
129560 mi

C $150
replaced defectivea aftermarket right side axle shaft to address vibration under load - repeat of repair from last year 

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2001 Volvo S60 4-door

turbocharged 5-cylinder automatic 2WD

95000 mi

US $4000
TOTAL transmission failure. Rebuild uneconomical - new transmission needed and installed. 
83080 mi

C $1600
Transmission failure due to gear slippage in gears 1, 2, and 3 (repair replaced the planetary gears and associated parts). 

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2001 Volvo S60 4-door

5-cylinder automatic 2WD

118000 mi Transmission failed, got rid of car. 

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Volvo S60 Transmission Problems

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