Most common 2002 Volvo S40 problems
Share of the 27 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Volvo S40 complaints by model year
Best S40 years: 2010, 2011, 2009. Years to avoid: 2000, 2001, 2005, 2006, 2004. Compare all years →
2002 Volvo S40 recalls (1)
Equipment › Other › Labels
Certain passenger cars fail to comply with the requirements of federal motor vehicle safety standard no. 225, "child restraint anchorage systems." the second isofix guide was not installed in these vehicles and, in certain cases, the owner's manual isofix information is incorrect.
Remedy: Owners will receive a letter/package consisting of the second isofix guide with installation instructions, and in certain cases, the corrected owner's manual May be provided.
What 2002 Volvo S40 owners say
Brakes
Tl contact owns a 2002 Volvo S40. While driving 30 MPH the contact engaged the brakes when the vehicle in front of her slowed down causing a crash. The vehicle failed to slow down when the brakes were applied. The contact was not injured. A police report was filed. The contacts vehicle had front end damages. The vehicle was repaired. The contact stated that a local mechanic replaced all of the left front lights, the hood, the bumper and the fender. The failure mileage was 104,000 and the current mileage was 104,900.
Tl* the contact owns a 2002 Volvo S40. The contact stated that the brakes were applied while reversing and the pedal traveled to the floorboard abnormally. The contact took the vehicle to a local mechanic where the mechanic advised that there was a crack in the master cylinder. The master cylinder was replaced however, the failure recurred while in reverse. The mechanic was contacted a second time who advised the contact of NHTSA campaign id number: 04V493000 (service brakes, hydraulic:power assist:vacuum:hoses, lines/piping, and fittings) and informed the contact to call a dealer. The contact called the dealer regarding the recall but the dealer stated that the VIN was not included. The vehicle was not further repaired. The failure mileage was 150,000. Updated 10/04/11 the consumer stated he was experiencing problems with the brakes on his vehicle. …
Electrical system
The horn failed to function properly when horn button was pressed from the left side. The horn did not work at times or excessive force was needed. Consumer was involved in a rear end collision in which he tried to use the horn but it didn't work. Vehicle was brought in several times but not repaired to working order.
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. …
Lights
Types of recurring issues with Volvo S40: headlights, driver front window motor, early brake pad wear. Headlight bulbs were replaced 2-3 times a year at consumer's cost. When brought to the attention of Volvo dealer they reported that it was probably due to lights being used during daylight. They check electrical and reported no issue. Had brake pad and rotor issued shortly after purchasing the vehicle. Volvo dealer reported Volvo rotors were built thin and soft. Cost of brake replacement was not covered under warranty as it was considered regular wear. Driver side window regulator has been replaced three times. First regulator was replaced in June 2005, then February 2006 and now May 2007. May 2007 regulator was at the cost of the consumer as warranty had expired and warranty on part only lasts 12 months even though there is an apparent problem.
I bought a 2002 Volvo S40 from an individual in January of 2004. In a matter of 3 months in 2005, I had to replace my passenger headlight 3 different times and my driver headlight 2 different times. I called the Volvo dealer and they said that a bulb should last around 2 years. In the next month, my passenger headlight went out again. I got under the hood to replace it as usual. When I pulled the black plastic piece that contains the male part to the wire connection and acts as the bulb socket, it was melted. It was melted to the point that I could not get the bulb out until I used pliers. I took my car to the Volvo dealer and they said that I would have to replace the whole headlight compartment. Since Volvo headlight compartments are "factory sealed", they would not break the seal. I would have to buy a brand new one @ $500. …
2002 Volvo S40 engines & fuel economy
| Engine | Transmission | Drive | MPG city / hwy / combined |
|---|---|---|---|
| 1.9L 4-cyl turbo | 5-speed automatic | FWD | 19 / 27 / 22 |
EPA ratings. Class: Compact car.
Frequently asked questions
Is the 2002 Volvo S40 a good car?
Based on 27 owner complaints filed with NHTSA, the 2002 S40 rates average: 1.3× as many complaints as a typical year of the S40 at the same age. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2002 Volvo S40?
The brakes — 7 complaints, 26% of all complaints for this model year, most often about foundation components › disc › pads. Next are the electrical system (5) and lights (3).
How many recalls does the 2002 Volvo S40 have?
There is 1 recall for the 2002 Volvo S40, the most recent from August 1, 2003 (labels). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Volvo S40?
The best years by complaints, compared at the same age, are 2010, 2011 and 2009. Years to avoid or approach with caution: 2000, 2001, 2005, 2006 and 2004. See the full Volvo S40 years comparison.
At what mileage do 2002 Volvo S40 problems happen?
The median mileage reported in complaints is about 48,000 miles; 56% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.