| 1 | 0 | 3 | 4 | 3 | 4 |
Expensive Volvo S40 repairs by problem area
Engine (27%)
Transmission and Drivetrain (12%)
Brakes and Traction Control (5%)
Suspension and Steering (19%)
Electrical and Air Conditioning (29%)
Paint, Rust, Leaks, Rattles, and Trim (5%)
Other (3%)
Chart based on 77 repairs.
Volvo S40 repair cost distribution
$2500+ (23%)
$1000 - $2499 (77%)
$500 - $999 (0%)
$100 - $499 (0%)
< $100 (0%)
Chart based on 43 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2009 Volvo S40 4dr Sedan
turbocharged 227hp 2.5L I5 5-speed shiftable automatic AWD
| 63500 mi US $110 |
Replaced TPMS Sensor |
| 120044 mi US $167 |
Replaced coolant reservoir |
| 122606 mi US $1106 |
Replaced AC compressor, compressor clutch worn |
| 123018 mi US $945 |
Replaced alternator |
| 136217 mi US $900 |
Replace front struts and springs |
2008 Volvo S40 4dr Sedan
turbocharged 227hp 2.5L I5 5-speed shiftable automatic AWD
| 63000 mi US $130 |
Rattle in front dash and windshield washer |
| 70100 mi US $675 |
Cracked Head light lense, Insurence paid for lense replacment. But bulb went out the next week and that was not covered and cost $425.00 |
| 86100 mi US $255 |
ABS sensor needed cleaned |
| 101500 mi US $650 |
xenon headlight out + replaced broken side marker light |
| 109000 mi US $875 |
Replaced Passenger front drive axle & Hub |
| 123300 mi US $650 |
Replaced original alternator |
| 156000 mi US $695 |
Rear break calapier went bad |
| 156000 mi US $1050 |
AC compressor replacment |
| 159000 mi US $1150 |
Head light lens cracked. I do not believe it was hit with anythink looked like a vertical stress crack. Middle stop light in the window out. Required special ordering of part and a full day in the shop, they had never changed one before. |
| 149000 mi US $549 |
Starter went out, Volvo shipped incorrect replacement had to wait and additional week for second replacement |
2008 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed shiftable automatic FWD
| 53000 mi US $1100 |
Strut bearing was making rubbing noise at low speed including parking. Required removal of strut/spring assembly. Replaced struts since everything was apart. Dealer had no clue. |
| 58200 mi US $600 |
Check Engine Light was going on/off. CAN-OBD2 scanner indicated P00089 - Fuel Pressure Regulator Performance. Expected cause was faulty fuel injection pressure sensor - common problem on S40s. Shop updated software with Volvo download. |
| 60300 mi US $900 |
Check engine light on with trouble codes. AC also stopped working at same time. Difficult for shop to troubleshoot. Suspected leak detection pump or ECM. Problem was a shorted sensor in oil pan. |
| 71700 mi US $750 |
Replaced alarm/siren module and main car battery, due to failure in our 2011 Volvo S40, which irreparably damaged the main battery. Main car battery was less than 2 years old and replacement cost was $225. |
| 75000 mi US $1100 |
Typical problem with Volvo S40 AC compressors. Clutch on AC compressor was not engaging during warm weather due to inability of electromagnet to close the gap. Problem has been solved by others by removing the clutch (using special or self-made tools) and closing the gap by changing or removing shims. Others have used used "bread clips" or thin metal sheets on the outside of the clutch. Decided to ask the Volvo expert mechanic just replace the entire compressor on the 2008 (and identical problem on the 2011 S40). Compressor part was $740. Only charged couple hours of labor and had him change the serpentine belt while he was working on it. Solved the problem so hopefully another 75000 miles of AC. |
| 80000 mi US $700 |
Replaced non-adjustable rear upper control links with adjustable versions. Allowed camber adjustment as the left rear wheel camber was out of specification. Rubber bushing on the sway bar end links was gone - shop tech noticed this when I brought the car in for annual wheel alignment. |
| 34300 mi US $1100 |
Condensor |
2007.5 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed manual FWD
| 21080 mi €2500 |
new ABS pump + ECU |
2007 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 6-speed manual AWD
| 80000 mi US $1000 |
Shaking on acceleration. This should not happen at only 80K miles. Replaced an axle and lower control arms. Repair took care of the problem. |
| 110000 mi US $350 |
XYB adjustable shocks replaced the Heico shocks on the lowered rear that were completely worn out. |
| 114000 mi US $500 |
Rear shocks went out & replaced with 3rd party adjustable shocks |
2007 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 5-speed shiftable automatic FWD
| 73100 mi US $600 |
Replaced PCV box Replace driver side trans axle and boot |
| 80000 mi US $285 |
Replace front motor mount |
| 80000 mi US $612 |
engine service urgent light on. Dealer changed fuel pressure switch and spark plugs. |
| 80000 mi US $899 |
Engine light on, replaced leak detection pump |
| 95000 mi US $428 |
Replace brake caliper |
2007 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 5-speed shiftable automatic AWD
| 106300 mi US $500 |
Previous owner's exhaust repairs without proper pipe alignment contributed to premature flex pipe failure at the manifold. Replaced flex pipe, repaired hangers, and realigned exhaust. Allowed mechanic flexible lift time between smaller jobs to save cost. |
| 109100 mi US $560 |
Replaced both (lower) control arms, as one exhibited excessive play. |
| 125000 mi US $200 |
Normal wear. Rear struts replaced, as they were failing. |
| 126000 mi US $1900 |
Replace failed PCV system. Replace right front wheel bearing. (Singularly expensive job) Install both provided front struts and strut bearings. Replace leaking camshaft seals. |
| 129000 mi US $900 |
Replaced rusted/patched factory cat-back exhaust with SS system. |
| 135000 mi US $560 |
Replaced front brake rotors and pads after snow tire swap shop overtighted lugnuts and warped rotors. Also full alignment. |
2007 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed shiftable automatic FWD
| 42000 mi US $100 |
Sun Roof Rails clog, interior leaking on passenger side. |
| 59000 mi US $1400 |
alarm module failure, battery replaced. software flash done. full 60,000 service completed. left front strut replaced, control arms replaced, right front shock leaking, both upper shock mounts replaced, alignment performed. coolant water bottle replaced. |
| 85000 mi US $100 |
I had a broken left axel repaired under warranty and 82000 service completed (another $583). |
| 85300 mi US $100 |
passenger side axel replaced and both left and right boots replaced. |
| 95500 mi US $1100 |
replace air box assembly. I was unable to remove the size 6 torq bolts the were striped and the inlet hose was deteriorated, it was unrepairable. replaced motor mount due to vibration at idle. replaced rubber door striping. |
| 113000 mi US $1400 |
112000 service, repaired replaced drivers side seat electrical panel, recovered drivers seat, installed new r model steering wheel. |
| 54240 mi C $1250 |
front wheel bearings had to be replaced. Front struts were replaced at same time as one was defective. |
| 63240 mi C $207 |
micro switch on to open the trunk died and needed to be replaced |
| 69380 mi C $330 |
PCV valve stuck open and a split hose |
| 93000 mi C $600 |
replace starter |
2006 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 6-speed manual FWD
| 30000 mi US $285 |
Sunroof drain clog, with 1" water in entire right side of interior (front & back). Carpets removed/dried, drain mechanisms replaced with updated parts, interior damage check, carpets replaced. |
| 31200 mi US $300 |
Electro-mechanical trunk lock shorted out and replaced. Long process to also diagnose wiring problem to the unit. Wire harness to trunk replaced. |
| 35200 mi US $100 |
A/C drains clogged. Condensation blowing out dashboard vents. Water in passenger compartment, carpets soaked. Repeat of sunroof drain clogs, water in passenger compartment. Dealer states repairs made to drain system. Seats, carpets removed, cleaned, dried, reinstalled. Electronic trunk latch activator handle replaced. This is the second time this problem has been addressed. In the first repair every part except the activator handle was replaced, but the problem reoccurred. |
| 39300 mi US $1300 |
Clogging and corrosion of A/C condenser to the point of failure with extensive water leakage into passenger compartment. Condenser removed, cleaned (extensive presence of mold) and re-installed. Carpets removed, cleaned, treated for mold. |
2006 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 6-speed manual AWD
| 105000 mi US $250 |
One engine mount was completely ruptured. |
| 121200 mi US $1000 |
New front shocks & struts |
2006 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 5-speed shiftable automatic FWD
| 26660 mi $200 |
Emission system noise. A valve was replaced (this is the 2nd time this happens). |
| 33480 mi $5000 |
Transmission |
2006 Volvo S40 4dr Sedan
99-horsepower 1.6L I4 5-speed manual FWD
| 85000 mi £1200 |
Failed wishbone bushes. Wishbones replaced. |
2006 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed shiftable automatic FWD
| 63240 mi C $272 |
front sway bar link kits |
| 70040 mi C $248 |
trunk lid kept unlocking. trunk switch was replaced. |
| 78000 mi C $425 |
A/C seals were leaking & replaced. A/C re-charged |
| 80600 mi C $1478 |
Passenger side rear brake squealing on breaking. Rear 80% pad left on drivers side, O% on passenger side - master cylinder issue. Rear pads, rotors and master cylinder replaced. |
| 91840 mi C $275 |
Accelerator pedal sensor failure. Pedal & sensor kit was ordered and installed |
| 92140 mi C $500 |
lack of cabin heat. Replaced thermostat, coolant recovery tank. battery would not charge - replaced battery |
| 91800 mi US $1000 |
AC clutch was not working properly and needed to be replaced. Cost for this alone was $860. Replaced fuse for the power outlets (ie. cigarette lighters). Cost was $50 bucks for a fuse!! |
| 100000 mi US $120 |
rear brake caliper replaced due to poor seal and leaking brake fluid. |
| 9000 mi US $13000 |
Acquired car. In first few weeks of use, needed to replace left trunk prop at dealer; good service & no cost. Considering purchasing extended warranty having read reviews from other owners. My mechanic also recommends warranty due to expensive parts. |
| 12000 mi US $200 |
Check Engine light illuminated. Gas cap needed to be replaced & then mechanic did analysis of car for other maintenance. |
| 13000 mi US $1200 |
Check engine light came on & then it stopped coming on after a few days. Mechanic originally forgot to read the code. Brought car back for code to be read & nothing was found wrong. Mechanic sprayed special chemical into intake vent to eliminate moldy smell in air conditioner. Was NOT charged extra for this, as we paid for everything else. Was also not charged for diagnosis code for check engine light. |
| 13000 mi US $1000 |
Oxygen sensor needed to be replaced per check engine light & diagnostics by mechanic. |
2006 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed manual FWD
| 95000 mi US $500 |
Shifter cables needed to be replaced. The coupling broke while shifting from first to second gear. |
| 147000 mi US $248 |
Battery was slowly failing after ten years (it was the original battery) |
| 157000 mi US $610 |
Check Engine light on, had state-required emission test done, had to replace the catalytic converter. |
| 119500 mi US $1074 |
CV boots were torn on both sides - replaced all four. |
| 170000 mi US $1490 |
Ignition coil #2 failed, needed to be replaced. $270. During repair service for ignition coil, they noticed my fuel pressure sensor was bad. Oil trap was clogged - technician noticed it while car was in for another repair. $700. |
| 189000 mi US $120 |
Broken engine mount, top, passenger side. Easy. |
2005 Volvo S40
Engine not specified
| 114700 mi £2000 |
4 new shock absorbers |
2005 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 6-speed manual FWD
| 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. |
| 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 |
| 49000 mi US $398 |
Fuel pressure sensor replaced |
| 54000 mi US $125 |
Software patch installed to fix AC sometimes blowing hot and cold at same time. Problem has happened twice. |
| 60000 mi US $1214 |
Air conditioner compressor replaced. Also leak onto carpet caused by AC drain hosed fixed. |
2005 Volvo S40 4dr Sedan
turbocharged 218hp 2.5L I5 6-speed manual AWD
| 47000 mi US $950 |
O2 sensor check engine light, dealer replaced battery harness and O2 sensor. |
| 89000 mi US $6700 |
Timing belt tensioner failed |
| 160000 mi US $100 |
Replace passenger front wheel bearing. |
| 164000 mi US $220 |
Replace PCV oil trap. Replace AWD controller and pressure sensor. |
| 169000 mi US $1200 |
Replace clutch, flywheel, slave and angle gear collar. Replace fuel pump |
| 58000 mi US $219 |
Intermittent Check Engine Light |
| 103000 mi US $700 |
Battery was leaking, corroded battery and battery cables were replaced. |
| 111000 mi US $1400 |
Alternator failed, replaced Alternator failed, killed battery Cam seal oil leak |
| 117400 mi US $400 |
Brake sensor replaced, reverse lights were intermittent. Engine mount damaged |
| 127000 mi US $350 |
Cracked Coolant Reservoir |
| 128000 mi US $300 |
InnerCV boot leaking |
2005 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed shiftable automatic FWD
| 138000 mi US $1200 |
transmission needed to be replaced |
| 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 |
| 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. |
2005 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed manual FWD
| 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. |
| 55000 mi US $550 |
one motor mount was degraded and required replacement. This was detected during a normal service interval. |
| 59400 mi US $960 |
Replaced worn lower control arm |
| 64100 mi US $175 |
I experience periodic blockage of the sunroof drainage tubes. Part of this service interval addressed this issue. |
| 82600 mi US $732 |
Headlining delaminating - replaced entire headlining. |
| 77800 mi US $140 |
Symptom was power steering pump stopped working. Diagnostic codes and battery load test indicated failing battery. |
| 92900 mi US $4200 |
CV boots replace engine mount strut shocks |
| 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. |
| 79000 mi US $350 |
Check engine light on. When tested, had error code ECM-2600. Replaced faulty fuel pressure sensor. |
| 80000 mi US $3500 |
No AC. Replaced condenser. $1700. Replaced shocks, discovered problem at tire shop, $1800. |
| 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. |
| 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. |
| 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. |
| 127000 mi US $1971 |
Intake manifold gasket, oil separator and gasket, spark plugs, air flow sensor. Camshaft and crankshaft seals. Right front axle. |
| 48980 mi C $1200 |
Front shocks need replacing |
2004.5 Volvo S40 4dr Sedan
168-horsepower 2.4L I5 5-speed shiftable automatic FWD
| 65000 mi US $140 |
Mod went wrong. |
| 140000 mi US $1800 |
replaced CEM (central electronic module) |
| 161000 mi US $150 |
Known problem Pcv |
| 165000 mi US $600 |
Head Gasket |
2002 Volvo S40 4dr Sedan
turbocharged 160hp 1.9L I4 5-speed automatic FWD
| 149000 mi US $1700 |
Replaced all 4 Brake pads, Rotors, and Brake Lines |
2001 Volvo S40 4dr Sedan
turbocharged 165hp 1.9L I4 5-speed automatic FWD
| 72000 mi US $1200 |
long crank time when trying to start, intermittent idle stumble. replaced fuel pressure regulator. |
| 72000 mi US $165 |
BOTH REAR TAIL LIGHTS NOT WORKING, ELECTRICAL SHORT FOUND AND REPAIRED |
| 105400 mi C $250 |
problem with flex pipe(?)/catalytic converter had been around a while but car sounded terrible and was reluctant to drive anywhere -- I had parts fixed rather than replaced since I hope to trade the car in during the next month or so... |
| 109740 mi C $1200 |
brakes did not work... brake lines replaced... also ball bearings replaced... |
See TrueDelta's information for all Sedans
See TrueDelta's information for all Volvo models.
