Selling a junk or non-running Volvo S40
Brakes are the S40 story in NHTSA's complaint file, and most of it sits in the first two model years. No S40 year tops the 2000, with 122 complaints. Of those, 44 point to the hydraulic service brakes. The 2001 brings another 24. That year also has its own recall, 03V474, for water getting into the electric brake vacuum pump.

- US model years (EPA)
- 2000-2011
- Complaints to NHTSA
- 506
- Year with the most complaints
- 2000 (122)
- Recall campaigns
- 13
- Component named most
- Service brakes (92)
- Generations
- 1995-2004 and 2003-2012
- Built
- 1,026,401, 1995-2012
If your S40 has reached the end, you can sell the whole car as it sits. We buy whole non-running and junk cars, with free pickup anywhere in the US.
Two different cars wearing one name
The S40 sold in the US from the 2000 to the 2011 model year, per EPA data, but it was really two cars. The S40 numbers here are owner reports NHTSA had received by October 10, 2026, and no single report proves a defect.
First generation: 2000-2003, plus some 2004s
Wikipedia dates this S40 to 1995-2004, with 1,000,034 built. It came mainly from the NedCar plant in Born, Netherlands, and was related to the Mitsubishi Carisma. Wikipedia adds that these were the last Volvos made at Born. It was front-wheel drive.
These years hold 251 complaints. Brakes lead on the 2000 (44), the 2001 (24) and the 2002 (5). Vehicle speed control shows up too, with 14 on the 2000 and 8 on the 2001, and suspension has 14 on the 2000.
Recalls on this body:
- 03V474 (2000): water in the brake vacuum pump. Dealers moved a new pump to a new spot. 36,000 vehicles in the campaign.
- 01V169 (2001): a diode in the climate control could wear out early; dealers added an adapter at the heater fan motor. 19,000 vehicles.
- 03V284 (2001-2004): a missing second ISOFIX child-seat guide. The 220,407-vehicle campaign may include other models.
- 03V424 (2003-2004): a fuel rail weld that could leak; dealers added a V-clamp. 15,067 vehicles.
The 2004.5 changeover
Wikipedia says the second S40 was first shown at the September 2003 Frankfurt show, built in Ghent from October, and put on sale part way through the 2004 model year, which is why some owners call it the 2004.5. So the 50 complaints on the 2004 cover both bodies. The 2004 also has 6 recall campaigns, more than any other S40 year. One of them, 04V493, was a vacuum hose non-return valve that could crack at a poor weld (1,719 vehicles).
Second generation: 2005-2011
This S40 was built in Ghent, Belgium, on Ford's Global C-car platform, and Wikipedia lists the V50, C30, C70 II and Mazda3 as relatives. Its 2011 engine table includes five-cylinder turbo versions. The S40, V50 and C30 were dropped in 2012.
These years hold 205 complaints, and electrical takes over from brakes: 16 on the 2005 and 19 on the 2006. The fuel recalls cluster here:
- 06V137 (2004-2006): S40 T5 turbo cars had a plastic fuel line tube by the turbo and exhaust manifold that the heat could damage. Dealers changed it to Teflon. 16,175 vehicles.
- 08V033 (2004-2006): the fuel pump electronic module could corrode in listed salt-belt states; dealers moved it. 23,000 vehicles.
- 08V101 (2007): a brake master cylinder seal that could wear early. The 1,114-vehicle campaign covers the C30, C70, S40 and V50.
- 08V329 (2008-2009): an S40 power steering return hose came through with a bad cure (1,020 vehicles).
- 10V255 (2010): a loose gearshift stud on 6-speed manuals; 536 vehicles shared with the C30 and V50.
- 10V591 (2009-2011): front power seat end stops (7,420 vehicles); 11V186 (2011): a possible crack in an engine bay support member, just 7 cars.
- 10V566 (2004-2010): Volvo told owners of Garmin 760 portable GPS units to stop using them because the battery could overheat (416 vehicles).
Fix it or sell it?
Set the shop's quote next to what a running S40 like yours goes for. If the quote gets close, selling it whole is usually the cleaner choice.
- Run the VIN at NHTSA's recall lookup. On a 2004-2006 T5, ask a Volvo dealer whether the fuel line and fuel pump module recalls were done.
- Hard brake pedal on a 2000 or 2001? That matches the vacuum pump recall. Our brakes guide explains the other causes.
- Lights, locks or gauges acting up on a 2005-2006? See electrical problems before paying for a long diagnosis.
- Still not sure? Read repairs that cost more than it's worth.
Complaints and recalls on the S40, year by year
These S40 figures come straight from the NHTSA database, pulled on October 10, 2026. The early S40s have been driving around longer than the late ones. An S40 recall often spans more than one model year, so the yearly recall figures share some campaigns.
| Model year | Complaints | Crashes | Fires | Injured | Recalls | Top component |
|---|---|---|---|---|---|---|
| 2000 | 122 | 12 | 1 | 3 | 1 | Service brakes (44) |
| 2001 | 84 | 11 | 4 | 5 | 2 | Service brakes (24) |
| 2002 | 27 | 4 | 0 | 2 | 1 | Brakes, electrical (5 each) |
| 2003 | 18 | 0 | 1 | 0 | 2 | Power train (5) |
| 2004 | 50 | 5 | 1 | 4 | 6 | Air bags, electrical (9 each) |
| 2005 | 81 | 2 | 0 | 1 | 3 | Electrical (16) |
| 2006 | 59 | 1 | 0 | 1 | 3 | Electrical (19) |
| 2007 | 25 | 4 | 1 | 5 | 2 | Brakes, electrical (4 each) |
| 2008 | 16 | 5 | 0 | 2 | 2 | Visibility, electrical (3 each) |
| 2009 | 10 | 0 | 3 | 0 | 3 | Power train (2) |
| 2010 | 9 | 1 | 0 | 0 | 3 | Structure, air bags (2 each) |
| 2011 | 5 | 0 | 1 | 0 | 2 | Electrical (4) |
| Total | 506 | 45 | 12 | 23 | 13 campaigns | Service brakes (92) |
Selling an S40 whole
- Gather the facts: model year (and whether a 2004 is the old or new body), VIN, mileage, and what's wrong.
- Request an offer online or call (877) 421-6008.
- Describe the spot. A 2000 with no brake assist can still be winched onto a truck; just say whether it rolls and steers.
- Don't strip it. Leave the engine, the converter and the wheels on, and mention anything already removed.
- Bring the title and ID at pickup. Without a title, read selling with no title. Afterward, check after you sell for plates and insurance.
More Volvos: the C70, C30, S60, S80, or the full Volvo list.
Questions people ask
- Which Volvo S40 year has the most NHTSA complaints?
- It's the 2000 S40, at 122 on October 10, 2026, with 44 citing the hydraulic service brakes. Next comes the 2001 at 84, then the 2005 at 81. Later S40s have been out for less time, but at this point the gap mostly reflects the cars, not their age.
- What was the 2000 S40 brake vacuum pump recall?
- Recall 03V474. NHTSA's notice says water can get into the electric brake vacuum pump and make it fail. Dealers fit a new, improved pump in a new location. The campaign lists 36,000 vehicles, which may include other models.
- Is a 2004 S40 the old body or the new one?
- It can be either. According to Wikipedia, the second S40 arrived in the middle of the 2004 model year, so some people call it the 2004.5 S40. Check the title or ask a dealer to decode the VIN.
- Will you buy an S40 that won't start or move?
- Yes. We buy whole non-running and junk cars, and you sell the whole car as it sits. We offer free pickup anywhere in the US. Say where your S40 is and if it can roll.
Sources
Every fact on this page comes from one of these. Checked October 11, 2026.
- NHTSA Office of Defects Investigation complaints flat file (FLAT_CMPL.zip), downloaded October 10, 2026 nhtsa.gov
- EPA fuel economy data: Volvo S40 model years fueleconomy.gov
- NHTSA: Check for recalls by VIN nhtsa.gov
- NHTSA recall 03V474: brake vacuum pump, 2000 nhtsa.gov
- NHTSA recall 01V169: climate control diode, 2001 nhtsa.gov
- NHTSA recall 03V284: ISOFIX guide, 2001-2004 nhtsa.gov
- NHTSA recall 03V424: fuel rail weld, 2003-2004 nhtsa.gov
- NHTSA recall 04V493: brake vacuum non-return valve, 2004 nhtsa.gov
- NHTSA recall 06V137: T5 turbo fuel line, 2004-2006 nhtsa.gov
- NHTSA recall 08V033: fuel pump module corrosion, 2004-2006 nhtsa.gov
- NHTSA recall 08V101: brake master cylinder, 2007 nhtsa.gov
- NHTSA recall 08V329: power steering return hose, 2008-2009 nhtsa.gov
- NHTSA recall 10V255: gearshift lever stud, 2010 nhtsa.gov
- NHTSA recall 10V566: Garmin portable GPS battery, 2004-2010 nhtsa.gov
- NHTSA recall 10V591: power seat end stops, 2009-2011 nhtsa.gov
- NHTSA recall 11V186: engine bay support member crack, 2011 nhtsa.gov
- Wikipedia: Volvo S40 (generations, plants, platforms, engines) en.wikipedia.org