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 2004 Volvo S60 problems
Coolant leaking from the front of the vehicle is often due to a leaking radiator, which must be replaced.
I have my 2006 Volvo s60 2.5t AWD serviced at the dealership per the recommended schedule in the Owner's Manual. Recently between the 37,500 and 45,000 mile service I noticed my "Coolant Level Low" light coming on about every 2 months but I park my car in a garage and have never seen any fluid leaking. I add the 50/50 coolant to the full level only to have to add it again in a few weeks. Today at my 45,000 service the Dealership tells me my ra...
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 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
Erratic shifting from the automatic transmission and cold start issues can sometimes be corrected by software upgrades to the engine and transmission control modules.
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.
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.