fairly significant
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
16,000 miles

About These NHTSA Complaints:

The NHTSA is the US gov't agency tasked with vehicle safety. Complaints can be spread across multiple & redundant categories, & are not organized by problem. See the Back button — blue bar at the very top of the page — to explore more.

Get notified about new defects, investigations, recalls & lawsuits for the 2002 Volvo S40:

Unsubscribe any time. We don't sell/share your email.

problem #3

Jun 062009


  • miles
Front end suspension isn't right, pulls when driving and there is a knocking items NHTSA 10016415 and 630879. Check engine has always been on 10003441. There is a clunking noise when shifting 10003398. There was never an accident these are just ongoing things and the suspension may cause an accident and check engine light is hard to get passed for inspection in nc.

- Raleigh, NC, USA

problem #2

Jun 012005

S40 4-cyl

  • 48,000 miles
In September of 2004, I began experiencing problems with my Volvo S40 sedan. The vehicle would shut off while I was operating it for no apparent reason. I took the vehicle to the dealer twice and then contacted the Volvo customer care department following an incident when the vehicle shut off while I was in a very busy intersection in town. I narrowly avoided a very serious crash. They sent a regional technician to the Volvo dealer. Volvo had the car for an extended period of time and said while they could not determine the problem, they replaced several parts. I experienced no further problems until June of 2005 when the exact problem resurfaced. When I took the car back to the dealer and contacted Volvo customer care, they indicated to me that they still could not tell what was wrong with the car and so they would not "throw parts" at a car. My husband and I are both in law enforcement and know firsthand the devastation of car crashes. We felt so unsafe in the vehicle, that we decided to trade it in July of 2005....a very costly and financially devastating result. (we lost over $4,300) however, I felt too guilty to sell the car to anyone privately. I was so disappointed that Volvo refused to deal with this problem and left me no other choices than to drive in a very unsafe car, or face financial devastation.

- Tallahassee, FL, USA

problem #1

Jan 202005

S40 4-cyl

  • Automatic transmission
  • miles
I have had to replace a headlight 3 times and a taillight 2 times, a console light, and the fuse to my cigarette lighter in my 2002 Volvo S40; 5 of these things in the last six weeks. The Volvo dealership says Volvo now ( they didn't specify any particular year of Volvo) are blowing headlights so frequently, that the customer reps keep headlight bulbs in their desk drawers and replace them for free. To me, this means either there is a significant problem with the Volvo voltage regulators or this particular Volvo dealership is putting me off to try keep this repair from being taken care of by my car warranty. I say this because the first time I asked about my lights blowing so frequently, they told me it was because light bulbs tend to blow in cold weather. The second time I asked, they said all Volvo were doing that. I looked on your site about safety recalls on Volvo and saw nothing about voltage problems. Tonight I have also sent an email to Volvo.com site so obviously I haven't gotten a response from them. Since safety lights (headlight and taillights) are an issue with the problem I'm having with my car and the Volvo dealership says it's a common Volvo problem, I thought I should pass this by your site to see what you have heard.

- Holly Pond, AL, USA