What is the 2001-2004 Volvo S60 Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000)?

Volvo recalled 2001-2004 S60 sedans sold or registered in hot-climate states as part of NHTSA campaign 09V483000. On affected cars, long-term exposure to hot climate and repeated temperature cycling, combined with varying fuel quality, can cause the fuel pump flange to develop cr… Severity: high.

What is the 2001-2009 Volvo S60 AW55-50SN 5-Speed Automatic Transmission and TCM Failure?

P2-generation S60s use the Aisin-Warner AW55-50SN 5-speed automatic. Two related failures dominate owner reports: the transmission control module (TCM), which is mounted inside the transmission case and bathed in hot ATF, develops cracked solder joints and internal failures, and… Repairs typically run $900-$4,500. Severity: high.

What is the 2011-2016 Volvo S60 "No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction?

P3-generation S60 owners report a sudden 'No Oil Pressure - Stop Safely' message on the driver information display, often with no prior noise or warning, and frequently while the engine still has oil on the dipstick. CarComplaints lists this as the number-one engine complaint on… Repairs typically run $250-$2,500. Severity: high.

What is the 2001-2009 Volvo S60 Rear Shock Tower and Trunk Floor Corrosion?

First-generation S60 models are prone to severe rust in the rear shock tower mounting points and trunk floor, particularly in salt-belt regions. Water intrusion through deteriorated trunk seals and blocked drain holes accelerates the corrosion. In advanced cases, the shock tower… Repairs typically run $500-$2,500. Severity: high.

What is the 2019-2020 Volvo S60 Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000)?

Volvo Car USA recalled 2019-2020 S60 sedans among several other models because the car's low-pressure fuel pump can blow a fuse and fail. When that happens the engine can stall. NHTSA's consequence statement is direct: a stall increases the risk of a crash, which is why this was… Severity: high.

What is the 2011-2018 Volvo S60 S60 Seat Belt Anchor Cable Fatigue — Safety Recall 20V378000?

S60 sedans from 2011 through 2018 are covered by Volvo recall 20V378000. The problem is the flexible steel cable that connects the seat belt to each front outboard seating position: Volvo reported that this cable may fatigue over time. If the cable has fatigued, the seat belt may… Severity: high.

What is the 2001-2004 Volvo S60 Electronic Throttle Module (ETM) Failure?

The 2001-2004 S60 (and other P2 platform Volvos) is notorious for ETM failure due to a design flaw in the throttle body electronics. The module develops internal solder joint cracks and corroded contacts, causing the car to enter limp mode, stall at idle, or refuse to accelerate. Repairs typically run $300-$700. Severity: high.

What is the 2019-2023 Volvo S60 T5/T6 PCV Oil Trap System Failure and Oil Consumption?

The positive crankcase ventilation (PCV) system oil trap on the S60 T5 and T6 engines fails prematurely, causing excessive crankcase pressure, oil leaks, and increased oil consumption. The oil trap membrane hardens and cracks, allowing oil mist to enter the intake manifold and be… Repairs typically run $400-$1,200. Severity: medium.

What is the 2019-2022 Volvo S60 T6 Twin-Charged Engine Supercharger Drive Belt and Turbo Oil Line Leak?

The T6 twin-charged (supercharger + turbocharger) engine in the S60 has two common issues: the supercharger drive belt wears prematurely and the turbocharger oil feed line develops leaks. The supercharger belt drives the Roots-type supercharger for low-RPM boost and begins squeal… Repairs typically run $200-$2,500. Severity: medium.

What is the 2001-2009 Volvo S60 Rear Electronic Module (REM) Water Damage?

The Volvo S60 P2 platform has the Rear Electronic Module (REM) located in the trunk area where it is susceptible to water intrusion from trunk seal leaks or condensation. Water damage causes intermittent electrical failures in rear lighting, fuel pump, and other circuits. Repairs typically run $200-$800. Severity: medium.

What is the 2001-2002 Volvo S60 2001-2002 S60 Throttle Software Recall (06V441000) — Limp Home Mode Without Cause?

The early S60 sedan, model years 2001 and 2002, was included in NHTSA recall 06V441000, a Vehicle Speed Control campaign Volvo opened on December 29, 2006. Per the recall summary, throttle position sensor irregularities, a dirty throttle housing, and/or inefficient software calib… Severity: medium.

What is the 2001-2007 Volvo S60 In-Tank Fuel Pump Module and Fuel Level Sender Failure?

Fuel system complaints are the single largest NHTSA category on the early P2 S60 (roughly 74 complaints on the 2002 and 92 on the 2001). Two distinct parts fail. The fuel level sender's resistive card wears where the wiper arm sweeps, so the gauge reads erratically, sticks full,… Repairs typically run $350-$1,100. Severity: medium.

What is the 2001-2009 Volvo S60 DIM (Driver Information Module) Instrument Cluster Solder Joint Failure?

The P2 S60's instrument cluster is a self-contained module (DIM) that sits on the CAN bus. Thermal cycling in the dash cracks the solder joints where the cluster's connector pins and internal components attach to the circuit board. The result is intermittent, then permanent, clus… Repairs typically run $250-$900. Severity: medium.

What is the 2001-2009 Volvo S60 Thermostat Housing Coolant Leak (Turbo 5-Cylinder)?

The plastic thermostat housing on P2-platform S60 turbo models (T5 and 2.4T) is prone to cracking and leaking coolant, especially as the housing ages and becomes brittle from heat cycling. The leak typically starts as a slow seep around the housing gasket or where the housing mee… Repairs typically run $200-$500. Severity: medium.

Volvo · Known Issues

2001-2025 Volvo S60 Problems: 24 Known Issues

2001-2025 model years · 1,770+ owner reports · Updated August 2026

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According to Au7o's analysis of 1,770+ owner reports, the 2001-2025 Volvo S60 has 24 documented known issues, with 13 rated critical. The most serious are Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000), AW55-50SN 5-Speed Automatic Transmission and TCM Failure ($900-$4,500 repair), "No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction ($250-$2,500 repair), Recall 04V451000: Electric Cooling Fan Overheating and Engine-Bay Fire Risk (2001 S60), ABS, ESC and Traction Control Loss From BCM2 Diagnostic Fault (Recall 23V012000), Rear Shock Tower and Trunk Floor Corrosion ($500-$2,500 repair), Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000), Recall 04V029000: Front Control Arm Stud and Nut Can Lose Tension, Risking Separation from the Spindle, . at .

Frequently Asked Questions

What are the most common Volvo S60 problems?

According to Au7o's analysis of 1,770+ owner reports, the 2001-2025 Volvo S60 has 24 documented issues. The most frequently reported are: Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000), AW55-50SN 5-Speed Automatic Transmission and TCM Failure, "No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction. Of these, 13 are rated critical and should be addressed promptly.

Is the Volvo S60 reliable?

The 2001-2025 Volvo S60 has 24 known issues documented across 1,770+ owner reports. 13 issues are rated critical: Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000) and AW55-50SN 5-Speed Automatic Transmission and TCM Failure and "No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction and Recall 04V451000: Electric Cooling Fan Overheating and Engine-Bay Fire Risk (2001 S60) and ABS, ESC and Traction Control Loss From BCM2 Diagnostic Fault (Recall 23V012000) and Rear Shock Tower and Trunk Floor Corrosion and Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000) and Recall 04V029000: Front Control Arm Stud and Nut Can Lose Tension, Risking Separation from the Spindle and Recall 25V179000 — S60 Plug-In Hybrid Battery Module Short Circuit (Do Not Charge) and S60 Seat Belt Retractor Fails to Hold a Child Restraint — FMVSS 208 Recall 21V682000 and S60 Seat Belt Anchor Cable Fatigue — Safety Recall 20V378000 and 2019-2020 S60 Automatic Emergency Braking Recall — ASDM Software Update (R29998) and Electronic Throttle Module (ETM) Failure. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Volvo S60 problems?

Repair costs for known Volvo S60 issues range from $0 to $4,500, depending on the specific problem and whether you choose DIY or professional repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Volvo S60 is the most reliable?

Reliability varies across model years of the Volvo S60. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2001-2025 Volvo S60 with 24 documented issues documented across 1,770+ owner reports.

All 24 Known Issues

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Frequently Asked Questions

What are the most common Volvo S60 problems?

Is the Volvo S60 reliable?

How much does it cost to fix common Volvo S60 problems?

What year Volvo S60 is the most reliable?

When Issues Typically Appear

S60 Seat Belt Retractor Fails to Hold a Child Restraint — FMVSS 208 Recall 21V682000#

S60 Seat Belt Anchor Cable Fatigue — Safety Recall 20V378000#

2019-2020 S60 Automatic Emergency Braking Recall — ASDM Software Update (R29998)#

Rearview Camera Image Fails to Display in Reverse (Recall 25V908000 / Volvo R10333)#

S60 Fails Rear Visibility Standard — Camera Image May Not Appear in Reverse#

"No Oil Pressure - Stop Safely" Warning and Oil Pump Pickup Restriction#

Electronic Throttle Module (ETM) Failure#

T5/T6 PCV Oil Trap System Failure and Oil Consumption#

T6 Twin-Charged Engine Supercharger Drive Belt and Turbo Oil Line Leak#

2001-2002 S60 Throttle Software Recall (06V441000) — Limp Home Mode Without Cause#

Upper Engine Mount (Torque Rod) Failure#

Fuel Pump Flange Cracking in Hot-Climate States (Recall 09V483000)#

Blown Low-Pressure Fuel Pump Fuse on 2019-2020 S60 (NHTSA 21V414000)#

In-Tank Fuel Pump Module and Fuel Level Sender Failure#

Recall 25V179000 — S60 Plug-In Hybrid Battery Module Short Circuit (Do Not Charge)#

Rear Electronic Module (REM) Water Damage#

DIM (Driver Information Module) Instrument Cluster Solder Joint Failure#

AW55-50SN 5-Speed Automatic Transmission and TCM Failure#

8-Speed Automatic Delayed Engagement and Hesitation#

Recall 04V451000: Electric Cooling Fan Overheating and Engine-Bay Fire Risk (2001 S60)#

Thermostat Housing Coolant Leak (Turbo 5-Cylinder)#

ABS, ESC and Traction Control Loss From BCM2 Diagnostic Fault (Recall 23V012000)#

Rear Shock Tower and Trunk Floor Corrosion#

Recall 04V029000: Front Control Arm Stud and Nut Can Lose Tension, Risking Separation from the Spindle#