One or both of the front wheel bearings may fail resulting in a rumbling noise from the front wheel area when driving over 25 mph.
Problems for specific Volvo S60 years:
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Newest reported 2002 Volvo S60 problems
Coolant leaking from the front of the vehicle is often due to a leaking radiator, which must be replaced.
Front struts are a real issue with the S60. I have a 2002 with 125,000 and just had the OEM struts installed a year ago by the dealer and they are already failing. The top of the strut is actually separating at the top and is visisble if you look at the strut tower from under the hood. My local repair shop reports actually seeing one break through the top and come through the hood. Dealer is telling me because the struts were put in 13 months ...
The automatic transmission may develop shifting problems and/or the Check Engine Light may illuminate due to internal component failure and/or software issues. It is always best to be sure the transmission control module has the latest software installed when any major transmission repair is performed.
The front control arm bushings wear out, resulting in alignment issues and squeaking and/or knocking noises from the front end. Worn bushings will require replacement.
The A/C Compressor will only work for only 5-10 minutes on hot weather days. Based on inspection, the AC compressor clutch plate gap is too big and the compressor is not functioning properly. Need to reshim the clutch hub and plate gap. Recommend to replace the magnetic clutch at the same time.
The Electronic Throttle Module (ETM) has a higher than normal failure rate. Volvo has extended the warranty on some of the ETMs to 10 years/200,000 miles
It is not uncommon for the exterior light bulbs to burn out prematurely. No repair option has been reported other than replacing the failed bulb.
Several complaints have been reported regarding Volvo S60 transmission shifting issues. Long shift times between gear shifts, hard shifting, hard downshifting and a loss of transmission operation all together to name a few.
If the issue is minor, a transmission software update may fix this issue. If available, the software should be updated before any repairs are made.
There are several technical service bulletins (TSB's) available from Volvo that address these shifting issues and they should be consulted by the repair shop during the automatic transmission diagnostic process.
Regular servicing of the transmission fluid can help with preventing transmission failure, but not in all cases. Follow the suggested fluid replacement interval recommended by Volvo. You will find this in your owners manual, or find it here: http://bit.ly/Volvo_Owners_Manuals
There is a computer that controls all these items and it's called the rear electrical module, or the "REM". To temporarily address this issue you can pull the fuse from the rear fuse box labeled "REM" and everything should start working again.
Volvo has updated software for the REM that will help prevent this from happening again. See a Volvo shop or Dealer and have this and all the software in the vehicle checked and updated every 30,000 miles.
Front upper strut mounts may wear prematurely, resulting in loud noise from the front of the vehicle when going over bumps.