2003 Volvo S40 problems

Filed Nov 7, 2021 · Engine · CA

Engine light stays on. I have had 2 mechanics check it out. They don't know why the light is on. I am very concerned about the fuel line problem.

Filed Dec 7, 2018 · Suspension · 120,000 miles · NY

The rear strut/shocks continue to break/crack over and over. I have gone through 3 new struts and shocks and they continue to break. I also have gone to the junkyard and all of the s40 and v40's have all of their struts/shocks broken. I've witnessed over 6 s40 or v40's like this now. My car has failed inspection because of this and it is a safety concern. It seems this is a common issue on every s40 and v40 from the years 2001-2004. It's absolutely ridiculous that these struts/shocks continue to break. There should definitely be a recall.

Filed Jan 31, 2018 · Acceleration, Electrical · 108,000 miles · FL

Prior to latest incident, the car had occasionally gone into "limp" mode, sticking in 3rd gear but drivable. That problem would go away after a day or so. Local shop couldn't find anything definitive. Bigger problem was yesterday evening's loss of throttle control and multiple electrical issues. Idle throttle setting (eg stopped at lights) became unstable, occasionally revving upto to ~2000rpm. Moments later on suburban divided main street, throttle stuck at ~2200rpm which meant I was doing 45mph (straight line) without any pressure applied to gas pedal. Slowed on the brakes until I shifted into neutral at which time everything died (electrical) and came to a stop, short of traffic lights. Time of incident approx 8pm est (dark), roadway fully lit thankfully. Car was pushed off street. Some electrics came back on when tried but full christmas tree lights (ie everything) across entire dash. Towed home. Removed ignition key (was inserted to ensure steering was unlocked) but radiator cooling fan remained on (engine hadn't run for 2.5 hours by that time). Pulled a fuse under the hood to stop it dumping the battery. Car is no youngster, manuf 2003 in netherlands, purchased second hand in 2005 with approx 20,000 miles on the clock. Currently at 108,000 ish. Other issues with car (not safety related) means I wont be having it fixed given its age and general cosmetic condition. It will be donated for scrap.

Filed Feb 8, 2013 · Electrical · 125,000 miles · VA

I returned to my car and found that I could not turn the ignition switch and as a result of the security system my car was totally inoperative. The car had to be towed to the nearest dealer, where it was diagnosed with a broken ignition switch, specifically the device that reads the chip in the key has failed and will not accept any key. Currently the car has been sitting at the dealer for over 4 weeks. Because the keys and switches are matched we cannot get an after-market replacement switch. Further, the parts are back ordered at the dealer, back ordered at volvo north america, back ordered at volvo in sweden, and they cannot even get me a date when the part might be available. As an reliability engineer, the ignition switch failure would be classified as a criticality 1, single point failure, in other words it results in loss of vehicle. There is no indication of pending failure, and no way to mitigate the problem if it occurs. You are stranded where ever the car was last parked. And worse, in this condition the car has no resale value, except maybe at a "chop shop", so I cannot even trade it in for a new car.

Filed Jun 29, 2012 · Acceleration · 94,000 miles · NY

Tl* the contact owns a 2003 volvo s40. The contact stated that while sitting at a traffic stop, the vehicle accelerated abnormally. The contact had his foot on the brake pedal and then had to shift into neutral to get the vehicle to slow down. The contact pulled the vehicle over, shut off and tried to restart the engine but it failed. The vehicle was towed to a dealer for inspection but the cause of the failure was unknown. The manufacturer was notified and they informed the contact that there were no recalls for the failure. The failure mileage was 94,000. The VIN was unavailable.

Filed Dec 10, 2010 · Transmission · 69,650 miles · CA

My 2003 volvo s40 has been driven fewer than 70,000 miles. All volvo recommended service has been performed by certified mechanics and is documented. My volvo dealer determined that the transmission had to be replaced. It is not at all reasonable to have a catastrophic transmission failure at only 70, 000 miles. I feel volvo should be responsible for at least the cost of the replacement transmission. In addition to the cost and inconvenience, this transmission failure presented a hazard that could have resulted in a serious accident. My volvo was being driven on a frontage road with the intention of entering a freeway. When the transmission started to slip, a right turn was made from the frontage road to a 4-lane road in an attempt to avoid high speed traffic. The transmission went to neutral during the turn and the volvo coasted to a stop just past the corner in the right lane of this busy road. Fortunately, a police car was just a hundred feet away, saw the volvo stop in the traffic lane and pulled in behind the stopped volvo with lights flashing to warn oncoming traffic. Only the proximity of the police car avoided being hit from the rear by vehicles traveling in the lane where the volvo stopped. The police called for a tow truck. I have determined that this type of transmission failure has been reported many times between 2003 and the present and feel it should be considered for a safety recall.

Filed Aug 9, 2010 · Engine, Fuel system · 85,106 miles · MI · fire

I was driving when the car start to accelerated by itself, accel pedal went to the floor. I could not keep a car even by the hand brake, so as it was jumping ahead. Then the car began to blow black and white smoke out under the hood. Some how I turn off the engine, took the key and run away from the car in the middle of the traffic road. Green liquid under the car. It died on the road. Police came, the car towed. After several days of checkout : t/3.8 checkout and replaced t-stat, temp sensor, t-stat housing gasket; bg coolant flush ; pcv; engine vent; engine mechanical; bg power steering; bg brake after a week I got the same--jumping, not stable, accel pedal goes to the floor. Internal short in cyl 3 and 2 coil and fouled sparkplugs t/1.5 replaced coil pack for cyl 3 and 2 and replaced sparkplugs.

Filed Mar 9, 2010 · Tires · RI

Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6) on feb 12, I had a periodic maintenance done at the dealership and they advised me that my tires were bad. I had only had the tires a short while so I brought the car to where I bought them (sears) and was advised that the tread was good but there was rot between the tread. The tires are bf goodrich traction t/a tires (my model p21550v16) and were sold nationwide by sears. Bf goodrich did give me a 45% credit but I feel these tires are dangerous since I was told they could shred at any time (sounded like firestone all over again). Bf goodrich no longer makes traction t/a tires but since the tires are 60,000 mile tires and I only got 35,000 on them and had them less than 3 years I thought your agency should investigate for a possible recall. Many people could be driving around on them without knowing how dangerous and hazardous they are. I initially sent a letter to your agency using the address from the website but it came back as not enough information provided. I hope this email will be as effective. The tires were not cheap tires and they were properly inflated and rotated so I never thought they would last such a short time (I purchased them on 4/22/07). I expect other people will feel the same and may not be as lucky as me to find out that these tires are bad and extremely dangerous. I have also sent this information to the ri attorney general's office. Any additional information that you require may be obtained by calling my cell at [xxx]

Filed Mar 19, 2007 · Transmission · 48,000 miles · MN

My 2003 s40 has been slipping gear between 3rd and 4th gear and ocassional hard shift between 2nd and 3rd gear. The car only has 49000 miles. I have gone to the dealer and they said, there is no software update for the TCM (transmission control module)and it needs to be replaced. Cost $800. This gear slip makes driving very bothersome and dangerous on occasion. If you need to speed up to get out of the way, the slip causes the car to lose power. Few seconds makes a difference between life and death. I have taken the car to another import repair shop and had them replace the TCM. Which did not help the issue. Then I took the car back to the dealer and asked to do another diagnostic to see if the TCM is the issue or not. They said, the TCM could not be functioning properly. They want me to replace the TCM through them and see if it will resolve the problem, otherwise it will be a transmission issue. I have researched on the web and through multiple forums, there have hundreds of issues related to TCM and transmission on these models. I do not understand how can a car have TCM or transmission issue with all it's factory recommended service done as scheduled.

Filed Dec 11, 2006 · Electrical · TX

Got a check engine light on and tried to get a full diagnostic test done, but the power control module was not communicating with vehicle.