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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Repairpal verified 2004 Volvo S60 problems
Coolant leaking from the front of the vehicle is often due to a leaking radiator, which must be replaced.
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.
Front and/or rear sway bar end links may wear out prematurely, causing a knocking noise from the front or rear of the vehicle when driving on bumpy roads. Our technicians recommend inspecting the links at each service, they should be replaced if any looseness is found.