2004 Volvo S60 Volvo S60 2004

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2004 Volvo S60 repairs by problem area

Engine (39%)

Transmission and Drivetrain (0%)

Brakes and Traction Control (4%)

Suspension and Steering (31%)

Electrical and Air Conditioning (0%)

Paint, Rust, Leaks, Rattles, and Trim (19%)

Other (7%)

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Chart based on 253 repairs.
See TSBs and recalls for the 2004 Volvo S60.

2004 Volvo S60 other repair cost distribution

$2500+ (8%)

$1000 - $2499 (8%)

$500 - $999 (0%)

$100 - $499 (33%)

< $100 (50%)

Chart based on 12 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

2014 Volvo S60 4dr Sedan

-horsepower 4-speed automatic FWD

11000 mi Right rear window popped when rolling up and down. Dealer R/R bracket. 
31000 mi The module that managed the keyless entry and engine start/stop was failing to detect my fob. 

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2013 Volvo S60

Engine not specified

8000 mi Loose bolt on frame causing audible body flex creaking on turns 

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2013 Volvo S60 4dr Sedan

249-horsepower 3.3L V6 4-speed automatic AWD

23000 mi keyless go for driver door stopped working 

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2013 Volvo S60 4dr Sedan

205-horsepower 3.2L V6 4-speed automatic 4WD, part-time w/low range

45500 mi Wheels were not round from prior pothole repairs. 

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2013 Volvo S60 4dr Sedan

-horsepower 4-speed automatic FWD

10000 mi sound from under the hood when you open the door. engine off, no keys in ignition. dealer says this is normal, but I've heard it in no others. 

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2012 Volvo S60 4dr Sedan

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

6300 mi XM Radio locks up and prevents you from changing stations iPod stops playing audio over the sound system when connected via cable after a minute or so especially when bluetooth is enabled. Ratting/creaking noise from rear of car Passenger side mirror makes jerky chattering noise when tilting 
8500 mi iPod playback issues over USB. Provided new version of Sensus at no charge. Ratting/creaking noise from rear of car Passenger side mirror makes jerky chattering noise when tilting 
12000 mi Steering wheel makes creaking noise when turning left or right Remote Lock/unlock feature not always working 
12700 mi Blind Spot Information System - message BLIS service required Creaking noise in steering wheel when turning left or right Remote not always working; after hitting info button, lights will intermittently turn off on the remote 
15000 mi Remote start range poor Steering not 100% on center after prior repair Bluetooth range poor / skips Auto up/down not working for passenger window - occasionally doesn't work for driver window Keyless entry does not work on driver side door handle 

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2012 Volvo S60 4dr Sedan

205-horsepower 3.2L V6 4-speed automatic 4WD, part-time w/low range

13660 mi Unidentified repair. 

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2012 Volvo S60 4dr Sedan

-horsepower 4-speed automatic FWD

18000 mi Driver side rear door would not lock. Technician found connection cable to be loose. Problem was corrected. 
25000 mi Metallic trim of steering wheel would flake off 
26000 mi Entertainment system could not put out any sound 
24000 mi Rubber seal around brake light on rear windscreen fell off 

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2007 Volvo S60 4dr Sedan

205-horsepower 3.2L V6 4-speed automatic 4WD, part-time w/low range

15000 mi *dup Radiator end cap leak. *dup Faulty fuel sensor in fuel tank was replaced. 
16000 mi

US $700
New radiator, after plastic radiator end cap in aluminum radiator came loose and coolant was slowly leaking (retarded design) Fuel pump replaced - fuel level integrated with fuel pump - was indicating tank empty whenever tank was below 1/4 (more than 3/4 empty). Also replaced kinked fuel lines (also defective from factory). Power steering line was incorrectly routed at factory and had minor kink as a result. Power steering line was re-routed according to manufacturer original specification - now un-kinked. 
27000 mi Leak in trunk from where spoiler attaches to boot lid. Dealer attempted to seal with butyl sealant. Did not seal all spoiler anchors. Others now leaking. Dealer will fix.  Multi function switch for left turn signal (where turn signal stalk attaches in steering column) malfunctioned frequently, and was replaced. 
28000 mi

US $60
Factory front mounted radiator suffered extreme corrosion due to road salt - paint was flaking off, aluminum was corroded. Removed faking paint. Treated with hexavalent chromium. Repainted with high-temp silicone paint. 
29000 mi

US $25
Windshield washer nozzle bracket holding driver side washer fluid spraying nozzle in place spontaneously broke. Nozzle did not spray onto windshield as a result of broken bracket. Bracket and nozzle are one piece, so replaced entire nozzle. 
24000 mi passenger door lock mechanism failed. Unable to lock or unlock door with fob or button. 
27000 mi Fuel pump replaced. Steering stops replaced Wiper blade hit trim. Not fixed. 
29000 mi Wiper arm was bent, fixed. Transmission shifting roughly. Could not replicate. 
32000 mi Yellow leak. Nothing found. Right rear headrest wouldn't stay up. Blocks in window replaced. 
35000 mi Headrest falls down by itself. New headrest was ordered. Trip computer was resetting by itself. Software was updated. Side hop issue. Was told that they would look into TNN and problem would be addressed when headrest was installed. 

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2007 Volvo S60 4dr Sedan

118-horsepower 1.8L I4 4-speed automatic FWD

36000 mi Headlamp washer pump replaced 
61300 mi Replaced front passenger seat belt Replaced seat rails for driver's seat 
122000 mi

US $450
replace driver side front hub & bearing replace struts 
144300 mi

US $785
Replaced headlamp assemblies. One was ruined when I hit a deer; replaced the pair. Replaced headlamp washer pump. It failed 
157000 mi

US $1200
Replace pads and rotors all the way around. Replace front brake hoses. Replace parking brake shoes 
55000 mi Cupping noise from passenger side wheel area. Noise occurs while driving at low speeds and going over small bumps and/or driveways. Dealer could not replicate the noise. Vehicle would not start on 4 occasions. I would have to pump the gas to get the vehicle to start on the 5th or 6th crank. Dealer could not replicate the problem and no code came up on the diagnostic test. 
76000 mi

US $1200
PCV hose was cracked and needed replacing. Intermediate service performed: brake fluid change, oil & filter change, check brakes, and change power steering fluid. 
102000 mi

US $900
Rear driver side door wouldn't lock. Rear driver side door lock replaced as well as driver side module & switch. 
103000 mi

US $2400
Front end was making a clunking sound over bumps. Had to replace front struts, spring seats, control arm bushings and replaced rear shocks as well. 

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2006 Volvo S60 4dr Sedan

turbocharged 257hp 2.4L I5 5-speed manual FWD

47000 mi I had the bulbs replaced in November - then the passenger side went out within two weeks and they said it was because the connector melted. Then it happened on the driver's side - but no melting. Now it has happened AGAIN. Replaced another headlight bulb, other side. Will be having more tests performed. 
47500 mi

US $113
Took to an ASE certified mechanic w/Volvo expertise to diagnose the premature light failure. Had to replace both bulbs on the right side and rewire the pigtail. Future repair needed on left headlight. 
62000 mi

US $1300
New alternator required. Noticed due to a whining noise. Could have continued to drive but it may have gone out at any time. Indicator signal had issues - intermittently would not keep the signal on, signal tempo would be irregular, etc. The strut holding up the hood was broken. 
81000 mi

US $100
Still being diagnosed. My mechanic replaced fuel filter but issue continued. Dropped offat Volvo on Jul 30 and they will run diagnostics on Aug 1. Has to do with fuel pressure and car stalling while accelerating or at a stop. 
82500 mi

US $1270
Broken engine mount Fuel pressure sensor not working Right front spring seat broken Excessive play in right front link rod 
84000 mi

US $400
Sun shade on moon roof would jam when trying to retract. Turned out that one of the plastic rails is slides on had cracked and needed to be replaced. 

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2006 Volvo S60 4dr Sedan

turbocharged 134hp 2.0L I4 Diesel 5-speed shiftable automatic AWD

30960 mi Engine warning light comes on. This is a recurring problem. light came on again after resetting of the computer. Performed computer diagnostic. No clear cause identified. Reset the computer again. 
34100 mi Engine light is always on. Shop has done the computer diagnostics on several occasions (5 so far) with no clear cause identified. After reset, the light comes back on within a few hours. Not sure if this is a hidden defect subject to recall 
41540 mi

C $800
Transmission fluid, winterize, and new battery 
42560 mi

C $500
Front end Connecting rod replacement. Reset on-board computer. Problem is apparently with an exhaust sensor that gives false readings. 
43400 mi

C $800
Replace front brake pads and shocks 
48980 mi

C $700
damaged rear spindle and hand brake mechanism 
50220 mi

C $500
Exhaust retention clamps broke 
52280 mi

C $1500
Ignition to steering interlock failed. Could not turn key past 1st position to start engine. 
52700 mi

C $40
Power Steering fluid leak. Hose and clamp replaced. 
54560 mi

C $980
Steering lock up due to failed seal in steering rack. Replaced with used rack unit (50% of price of new factory part). Had to wait 3 days to source part. 
56420 mi

C $100
Replaced tail Pipe clamp. 
57960 mi

C $804
Replaced right rear spindle, failed due to rust damage. Note( left rear previously repaired in 2013) 
59520 mi Rear wheel bearing replacement (left) 
60760 mi

C $450
Check Engine light/CO2 Sensor replaced 
61380 mi

C $1300
Haldex Differential Electronic Module 
64480 mi Impending repairs prompted sale of car. 

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2006 Volvo S60 4dr Sedan

118-horsepower 1.8L I4 4-speed automatic AWD

103000 mi

US $500
A bad ball bearing was creating noise. A clip holding a brake pad had broken off.  
106000 mi

US $175
Bad ball bearing discovered and replaced when snow tires were changed. 
110500 mi

US $200
Parking brake broke such that car wouldn't move. Evaporative leak causing Check Engine light to come on. 
131000 mi

US $3150
Initial problem was insufficient cabin heat. Bad cabin thermometer. Bad fuel pump, replaced timing belt. 
143000 mi

US $190
I don't remember. 
145000 mi

US $319
Tie-rod replaced. 
101000 mi

US $300
I don't remember what the problem was but they recommended more than I could financially handle so they agreed to repair what they could to ensure the car was safe and recommended I return for the remaining work. I just don't remember and can't locate service record for this. There was so much noise generated by the car and it continued even after repairs were made. 
109000 mi Car didn't drive well. The mechanic informed me the car was not safe to drive faster than 30-40 miles an hour, that it needed a great deal of expensive repairs and suggested I immediately trade the car. 
101000 mi

US $50
AWD went out Radiator slow leak $900 estimate. 
105000 mi Washer fluid bottle broken, leaks 
120000 mi

US $1170
Upper strut mount passenger side PCV system including breather box $550 

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2006 Volvo S60 4dr Sedan

-horsepower 4-speed automatic FWD

9300 mi Fuel door hinge replaced. 
11160 mi Indicator relay in dashboard replaced. 

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2005 Volvo S60 4dr Sedan

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

43000 mi

US $5
Loose vacuum lines underneath the chassis, which were easily secured using standard metal P-clips from the hardware store. 
66000 mi got a check engine light,took the car to the shop for diagnosis. They got a "missing or faulty gas cap" code,but did not find a problem. 
66700 mi Check engine light on again. Again diagnosed loose/missing gas cap code. Found faulty evap system leak detection pump. Replaced pump. 
89000 mi

US $166
intermittent "Reduced Engine Performance" message,rough idling. Removed throttle housing and performed cleaning operation per Volvo specs. Installed throttle body gasket. 
95000 mi

US $350
Key would not come out of ignition. Disassembled steering column found shift interlock cable binding not allowing key release. Disassembled center console found release mechanism binding.Cleaned and lubricated. 
101000 mi

US $800
radiator has a leak needs to be replaced.Will do in near future.Radiator R&R estimate 800.00 Remote only unlocks driver door. Traced source of problem faulty UEM. Estimate to R&R and load software 830.00 Steering wheel loose. Removed air bag module to access nut for steering wheel and tightened. 
145500 mi

US $1135
replace lower control arm bushings R&R Broken strut mount replace split hose from oil trap to cam cover 
177500 mi

US $1221
Intermittent check engine light for several months. Found codes related to fuel pressure module and sensor. New fuel pressure sensor, harness adapter,control unit. remove and relocate replacement fuel pump module. 
204000 mi

US $637
broke front passenger door window regulator trying to open window when frozen. R&R Window regulator 
204000 mi

US $350
Heard noise during maintenance inspection.Parking brake shoe on passenger side fell apart.R&R both rear parking brake shoes 

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2005 Volvo S60 4dr Sedan

turbocharged 134hp 2.0L I4 Diesel 5-speed shiftable automatic FWD

61000 mi

US $300
MAF sensor failure 
61000 mi Power steering pump leaking, tightened connectors, will observe. 
67000 mi

US $750
MAF failure, replaced with used MAF. 
75000 mi

US $5
Leak in windshield washer fluid system. 
77000 mi

US $100
Windshield washer pump corroded, breaking the tank in the process. Replaced with used tank from a junk yard and an OEM pump. 
81000 mi

US $1000
Radiator leak 
82300 mi

US $150
Rear muffler corroded, replaced with aftermarket unit. 

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2005 Volvo S60 4dr Sedan

-horsepower 4-speed automatic FWD

84000 mi

US $276
Radiator Fan noisy - replaced under warranty Repaired headlight washer nozzle, pump and cover 
86000 mi Moon roof would not open - previously repaired under extended warranty at same dealer in Dec 2010 Repair sun roof - broken again - will repair under warranty (I hope) 
95700 mi

US $200
Noise in front end - replaced front strut top end bushings, performed 4 wheel alignment. Replaced from pads and rotors. Removed, cleaned and reinstalled E brake (rear) to correct wheel dragging of one rear wheel. 
102000 mi

US $1750
Repair sun roof Replaced 2 horns 
103000 mi

US $680
Replaced torn CV joint left front wheel 
107000 mi

US $225
Noise in steering column 
108000 mi

US $100
Repaired noise in the steering column. Charged me only for the deductible on the warranty even though it was not covered since they had tried unsuccessfully to fix previously. 
110000 mi

US $250
Steering universal joint in the column was binding causing the wheel to not return to center position. 
120300 mi

US $850
Check engine light - Continuous Variable Valve Timing system - diagnosed positive vacuum - replace oil separator trap - cleaned CVVT valves - no help - suggested $2000 repair (hubs/valves) - my mechanic is checking timing belt-jumped tooth? 
123000 mi

US $680
Replaced CVVT intake and exhaust valve/solenoids to address check engine light. 
126000 mi

US $758
*d Replace both Variable Valve Solenoids. 

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2004 Volvo S60 4dr Sedan

turbocharged 197hp 2.4L I5 4-speed automatic FWD

82000 mi

US $400
Inside door handle of right rear door was not working. Turned out to be a broken cable inside door. 
95000 mi

US $100
Engine mount bushings were worn out; new upper engine mounts (with new design) installed. Lower transmission mount bushing worn out. Mount replaced with new part of a new design. 
101000 mi

US $1800
Broken driver's door handle. Cable had slipped inside door; reattached Lower control arm bushings worn out. New lower control arms installed.  
131000 mi

US $1300
Front strut blown out on rough roads. Strut and other assorted suspension pieces replaced.  
141000 mi Excessive travel in parking brake cables. Cables adjusted. Headlight wipers not functioning. Had them removed to meet Maine's inspection standards. 
147000 mi

US $20
Windshield washer had stopped spraying, took it in for possible motor replacement, but it turned out to be just a blown fuse. Put in a new fuse and all was working again. 
156000 mi

US $200
Bushing was worn in the front endlink, apparently a known Volvo problem. Endlink was under 1 year warranty from the shop, so I only paid for the bushings and the labor, the shop picked up the link cost. 
103000 mi Had a problem with an intermittent check engine light flagged as the MAP sensor (P2207). Dealer said to fix, but independent mechanic that the code was in error. 
111000 mi

US $400
Replaced all engine mounts, transmission mount, and subframe bushings as they were very badly worn out. 
121000 mi

US $400
*duplicate Replaced engine mounts, torque mount, and subframe bushings. 
125000 mi  
130000 mi

US $150
Engine codes for the MAP sensor were returned once more. The shop ran some diagnostics and flashed the software, but car started exhibiting a new problem of occasional violent shaking. Shop said that this was an "old" problem, charged 150. 
35960 mi Replace driver side wiper arm 
37200 mi Replaced window seal drivers door. 
38440 mi

C $120
Worn suspension bearings. 
39680 mi

C $73
Replaced cracked centre mount and speaker grille in dash. 
42780 mi

C $100
*4 wheel alignment 
44640 mi

C $79
*Factory scheduled maintenance interval. 
45260 mi *Wheel Alignment. 
48980 mi

C $72
Replaced broken driver side wiper. 
51460 mi

C $274
Replacement of broken power folding mirror assembly. 
57040 mi

C $139
Replaced upper radiator cooling hose. 
59520 mi

C $250
*duplicate Replacement of drivers side front ball joint. 
60140 mi

C $250
Replace driver side ball joint 
64480 mi

C $172
Replaced rear sway bar link arm, due to component failure. 
69440 mi

C $168
Replaced passenger side rear shock. The original one had failed (loss of damping). 
73160 mi

C $1600
Check engine light. MAF worn out. Mass air flow sensor replaced. During same visit found that PCV system was plugged. Entire PCV system replaced with new one. 
78120 mi

C $120
Replace drivers door check (arrests door when opening). Replace worn bolt on transmission mount. 
81840 mi

C $1800
Replaced strut mounts, spring seats, and front control arms. 
88040 mi

C $429
Replaced driver side front wheel bearing assembly 
93620 mi

C $300
Replaced ignition lock cylinder. Original one was starting to stick when the key was turned. 
94240 mi

C $600
replacement of worn engine mount. replacement of failed power steering system valve, fluid reservoir, and hose. 
100440 mi

C $92
Replaced turbo control valve replaced rear e-brakes and cables. e-brake cable had broken, causing e-brake shoes to get damaged as well. 
103540 mi

C $87
Replaced sway bar end links. 
105180 mi

C $500
replaced front CV axles (both sides) 
108460 mi

C $31
Repaired rattling roof trim pieces. Replaced broken plastic clips on roof trim. They had cracked on their own due to extremely cold winter. 

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2004 Volvo S60 4dr Sedan

turbocharged 134hp 2.0L I4 Diesel 5-speed shiftable automatic FWD

33000 mi The ABS system had a part that had to be replaced. The gas hose falls into the body of the car, has to be pulled out. 
72000 mi *60K MAJOR SERVICE PERFORMED, ALBEIT A LITTLE LATE..BRAKES NEEDED REPAIR BUT DECLINED DUE OT DEALER COST 
169300 mi

US $6500
Replace Transmission Replace Catalytic Converter 165000 mi service Replace Turbo return pipe seals Replace front Brake pads and Rotors Replace Brake vacuum pump switch Replace front driver seatbelt latch 

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2004 Volvo S60 4dr Sedan

turbocharged 134hp 2.0L I4 Diesel 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. 
115000 mi

US $650
Replaced suspension part, forgot what it is called 
133700 mi

US $130
Replaced driver side rear view mirror. The glass of the mirror simply dropped out...it delaminated. 
136000 mi New battery installed 
138700 mi

US $3000
Bevel gear was replaced after failure 

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2004 Volvo S60 4dr Sedan

205-horsepower 3.2L V6 5-speed manual 4WD, part-time w/low range

112000 mi

US $600
Timing belt, idlers, water pump, serpentine belt, spark plugs, upper engine mount replaced lower control arm drivers side front because rubber bushing wore out replaced emergency brake cable which seized up. 
113000 mi

US $20
Passenger window plastic mounting blocks cracked causing window to fall inside door. 
115700 mi

US $300
inner and outer tie rod ends with alignment right front wheel bearing very noisy 
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. Replaced lower ball joint. 
129700 mi

US $600
Owner Replaced rear springs, struts, strut top mount and rear sway bar ends 
134000 mi

US $700
Front struts, springs and support bearing. RF lower control arm. Had inferior aftermarket arm install about 30k MILES ago. 
143000 mi

US $350
Replaced crank case vent system including hoses and plastic tank located under intake manifold. Replaced hoses for the fuel evaporation system on the engine which were in poor shape. Replaced thermostat since I had to remove for other work. 
65300 mi

US $100
Replaced turn signal assembly due to intermittent left turn signal function. 
65700 mi

US $30
Replaced both windshield washer nozzles - one cracked and not completely attached, the other was not dispensing with maximum power. 
66000 mi

US $40
Replaced two ignition coils and all spark plugs due to misfire. Driver and passenger front windows both derailed due to improper re-installation of window trim by tinting shop. Replaced all four nylon regulator sliding blocks. Replaced trunk assist struts due to weak original units. 
70000 mi Stock radio stopped working. Pulled the relevant fuses and found no breaks, so I re-inserted. Radio started working again. 
71000 mi Display on stock radio went out, but sound was still playing and volume/station could be adjusted. After shutting off car and restarting, the display worked again. 
73000 mi

US $800
Repair/replace leaking angle gear seal Replace worn driver's side ball joint, replace both front electronic struts and spring seats. 

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2002 Volvo S60 4dr Sedan

turbocharged 247hp 2.3L I5 5-speed manual FWD

89000 mi

US $200
Upper spring and strut seat replaced. 
101000 mi

US $1500
Old struts and shocks worn - replaced with Bilstein. Note - old struts wore quicker because car was lowered and they were original. Tie rods replaced. 
108000 mi

US $100
TCV (waste gate solenoid) starting to fail. Replaced with IPD Heavy Duty TCV in anticipation of further modifications 
110000 mi

US $2000
Slave Cylinder failed at 109,000 miles. Clutch, slave cylinder, throwout bearing replaced. Flywheel resurfaced. 
111000 mi

US $100
CEL and hesitation. MAP sensor repaired 100 dollars and less than 1 minute 
115000 mi

US $250
spring seats with only 10k failed - manufacturing issue - mechanic paid for 1/3rd (full price of parts) owned paid for labor. 
129000 mi

US $200
Drivers side door handle did not open door - repair required replacement of entire door panel - mechanic repaired utilizing zip ties at fraction of cost. 

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2002 Volvo S60 4dr Sedan

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

64000 mi

US $781
Column lock replacement. Safety interlock cable replacement. 
64000 mi

US $800
Oil leak at turbo seal. 
87000 mi

US $295
Gas filler door fell off, when opened in our driveway. Therefore it was recovered undamaged, but required parts to re attach it. 
88000 mi

US $740
Drivers heated seat failed; not repaired due to cost 
99000 mi Driver's heated seat did not work. Suspension worn out. 

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2002 Volvo S60 4dr Sedan

-horsepower 4-speed automatic FWD

78000 mi Driver side door handle not functioning. Originally repaired with wire holding mechanism in broken clip. Repaired permanently with cotter pin after drilling into broken clip and glue on other side. 
82000 mi

US $30
Vacuum leak discovered at original gas cap. Gas cap replaced. 
83000 mi Service Alarm System. Alarm goes off with key fob but not when locked door is opened from inside. Needs new module. 
97000 mi

US $560
Left turn signal with bright switch not functioning. All 5 solenoids and spark plugs needed to be replaced. 
98000 mi

US $96
Battery would not start the car every time. May have been weakened by the air ventilation sensor when engine turned off. 
111000 mi

US $850
Right Fr. wheel bearing bad. while inspecting they found left frt. CV boots bad, so replaced and repacked 
119000 mi hood cable broke, dealer ordered parts, I installed  
116300 mi Started smelling gas. Recall fuel pump replaced. CAR WOULDNT START 
124300 mi

US $5400
I mentioned when going over pothole (etc) car would feel like I was driving on ice or oil for a second or two. my tires were bad, sd I was going to get new ones. Only changed oil. Next day I got 4 new tires and technician told me drivers side wheel was loose and wobbley, told me to go straight to shop and get it fixed. Ball joint broken. I had both front ones replaced. 
97000 mi

US $300
Replaced EVAP Purge Valve; also replaced fuel pump as part of a recall. 
103000 mi

US $1600
Fast idle. Replaced vacuum elbow. Adjusted and aimed headlights Replaced right front inner steering arm. Steering arm had play. Replaced left front ball joint Left front control arm bushings were found to be worn out; replaced. Worn out serpentine belt tensioner was replaced. 
104000 mi

US $155
A/C was not blowing as cold as it should; system was recharged and nothing else was found to be wrong with it. 
110000 mi

US $400
Power steering pump made rattling noise. Pump was replaced with warrantied used pump. Replaced power steering fluid as well. 
110700 mi

US $300
Parking brake suddenly locked up on one wheel during shopping trip. Car towed to dealer, found parking brake pads had delaminated. Replaced parking brake shoes and cables on both wheels and adjusted. 
101000 mi

US $610
Wiring from central electronic control module was severed. Short was found, wires battery and spark plugs replaced. 
104000 mi

US $270
minor transmission leak from axle seals. also passenger axle had a dislocated joint. replaced axle and both seals. 
108000 mi both front door handles came undone, doors could only be opened from outside 

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2001 Volvo S60 4dr Sedan

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

87420 mi 1) boot unable to open 2) driver door latch broke 
98580 mi

$200
Problem resolved itself after several days. Could have been caused by bad contact or moisture. 
99820 mi

$1600
Loss of power experienced after more than 30 minute drive or when hot. Checked MAF sensor, replaced Manifold intake sensor. Replaced heater hoses. Problem remains. 
104160 mi

$4000
Transmission failed and replaced. Later replaced two more times under warranty. 
104780 mi

$2000
Engine power loss when warm,wiring harness replaced, ignition coil replaced,ECU repaired,all sensors checked and replaced. Finally traced to a relay type valve above the camshaft. *d 
105180 mi

$150
Replaced failed turbo intake hose. 
114080 mi

$875
Trans fluid contaminated because of broken breather valve. Drained and refilled 4 times. Breather valve was replaced. Heater under dashboard leaking. Heater hoses were bypassed. 
116120 mi

$350
Alternator failed. 

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2001 Volvo S60 4dr Sedan

turbocharged 247hp 2.3L I5 5-speed manual FWD

113000 mi

US $274
*I had gotten the timing belt, tensioner and serpentine belt replaced a few months back (at 100k). Noticed it was noisier with new belts, but ignored. This week the serpentine belt came off while driving. Apparently they had not put it on properly and 
113000 mi

US $1045
Car was rattling and squeaking over bumps, especially when cold. Replaced struts and mounts on both sides. Also power steering hose was leaking and was replaced (have had 4 hoses and several clamps over a couple of years - I suspect a poor design puts pr 
126000 mi

US $135
Compressor won't stay on. Cools for 15 minutes then quits. Refrigerant was low, replaced low end valve. Air did blow cooler, but still compressor cut out. 
127000 mi

US $1100
Compressor clutch was bad. Replaced compressor and drying unit. 
128000 mi

US $57
Low oil pressure. None registered on stick. Did oil change. Seems to be burning oil. 
131000 mi Loose connection in frt suspension caused loud scraping/grinding noise. Sounded like the wheel would fly off any minute. Shop tightened everything up and noise went away. Right headlight and turn signal are intermittent. May be on when leaving house, off when arriving at work. Turn signal also goes on and off, but not at the same times as headlight. Can't find loose connection. 
138000 mi Check engine light. Code was for low turbo boost. Not repaired ($$$). Also burning oil. Light comes on when you are already 3-4 qts low. Added 2 qts last mo, 3 qts this month. No puddle. Shop ordered valve seals, assumes leak.??? Car pulls sharply right. Went for alignment 3 times, but computer shows not out of alignment. Seems to be steering or suspension. Going through tires fast. Shop had no solution. Got rotors turned to make sure no dragging, but didn't help. 
139000 mi

US $10
Warning: coolant low, stop safely ASAP. This has happened a few times. Added coolant, but can't tell where I'm losing it. Also burning a lot of oil, so adding several qt between changes. 
147300 mi

US $600
Replaced front control arm parts with used ones from the junkyard. Were replaced with new when car was younger, but they bent again. Went cheap this time. Ready to sell.  

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2001 Volvo S60 4dr Sedan

-horsepower 5-speed manual FWD

117180 mi

C $203
Right rear shock absorber failing; replaced rear shocks with OEM equivalent parts. 
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 
122760 mi

C $40
Replaced broken/failing trunk lid struts with aftermarket parts. 
124460 mi

C $150
replacement of driver's side axle shaft 
126480 mi

C $150
Right side outer tie-rod worn. Replaced inner and outer tie-rods. Alignment not yet performed. Worn transmission mount - replaced. 
127280 mi

C $100
replaced ball joints 
129560 mi

C $150
replaced defectivea aftermarket right side axle shaft to address vibration under load - repeat of repair from last year 
130200 mi

C $500
Replaced original exhaust system with "cat back" aftermarket system. Outer shell of the front resonator had come off entirely, and the muffler was cracked and rusted through in a couple of spots. It failed very slowly, over a period of about three years. 
151440 mi

C $300
Leaking water pump; water pump replaced. Intermittent headlight failure; cracked headlight lens (from stone). Replaced wiring connector for low beam bulb; replaced headlight lens with aftermarket part. 
156860 mi

C $40
replaced driver's side swaybar endlink. 
162440 mi

C $160
Regular brake pad replacement necessitated replacement of front brake calipers and flex hoses - caliper seals started leaking when pistons were pushed back. Three year old tie rods had low quality seals; wear was occurring; replaced with better quality parts before any risk of failure. 
166120 mi

C $215
Replaced front (upstream) oxygen sensor. 

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2001 Volvo S60 4-door

6-cylinder automatic AWD

102000 mi Heater core replacement Car stalls at all stops, CE light and emission service system required message 

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2004 Volvo S60 Other Problems

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 2004 Volvo S60 problems occur, check out our car reliability stats.