EXPERT IN AUTO PARTS
22 October 2025 (updated) Table of Contents
The automatic transmission of the Volvo S60 shows frequent faults, especially in the D5 2.4 diesel models and the 2.0 T gasoline models. The automatic transmission does not shift properly, gets stuck in a gear or exhibits jerky movements when changing gear. These symptoms typically occur between 80,000 and 120,000 km, but can also occur earlier with intensive use. The reliability of the transmission suffers particularly in stop-and-go traffic and irregular oil changes. In the 2.5T models, problems with the torque converter have also been documented, resulting in vibrations and delayed gear changes.
A systematic check is essential for the longevity of the transmission system. The sensitive Volvo S60 automatic transmissions require regular oil changes every 60,000 km and professional diagnosis at the first sign of shifting problems. Preventive maintenance with special oil and timely replacement of the transmission filters can significantly extend the service life and avoid costly repairs.
The air conditioning system of the Volvo S60 does not work properly, especially in 2004 and early models. Common complaints include poor cooling performance, unusual noises from the blower or complete failure of the cooling function. These faults typically occur between 60,000 and 80,000 km, with a second wave of problems documented around 150,000 km. The compressor often fails due to wear of the internal seals, while the condenser coils are damaged by stone chips or corrosion. The D3 and 2.4 petrol 170 hp models are also known to have problems with the climate control unit, leading to erratic temperature control.
Regular maintenance is crucial for the optimum functioning of the air conditioning system. The Volvo S60 air conditioning systems require annual inspections with refrigerant testing and cleaning of the condenser coils. Professional maintenance every 24 months with replacement of the cabin filter and disinfection of the system prevents bacterial contamination and ensures the longevity of the components.
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-41%
RIDEX Tyre pressure sensor (TPMS)
with groove, with valves
Article number: 2232W0084
compared to
RRP
£43.80
£25.49£101.96 / Price per 4 items
price incl. 20% VAT, excl. delivery costs
-21%
Article number: 1496
compared to
RRP
£23.65
£18.49
Price per item
£73.96 / Price per 4 items
price incl. 20% VAT, excl. delivery costs
-44%
ELRING Gasket, cylinder head
1,4 mm, Ø: 76,3 mm, Multilayer Steel (MLS), Notches/Holes Number: 4
Article number: 718.341
compared to
RRP
£45.60
£25.49price incl. 20% VAT, excl. delivery costs
MOBIL Engine oil
10W-40, 4l, Part Synthetic Oil
Article number: 150865
£24.49
£6.12
for 1 litre
price incl. 20% VAT, excl. delivery costs
SKF Bellow Set, drive shaft
146 mm, with clamps
Article number: VKJP 01001
£14.49£28.98 / Price per 2 items
price incl. 20% VAT, excl. delivery costs
The electric tailgate of the Volvo S60 shows recurring breakdowns, which manifest themselves in incomplete opening or closing. The tailgate often stops in the middle of its movement or does not respond to remote control or interior switches. These symptoms mainly occur between 70,000 and 100,000 km, with a second problem phase around 180,000 km. The weak points lie in the hydraulic cylinders, which become leaky due to wear of the seals, and in the electrical connections, which corrode due to moisture. The system is particularly vulnerable at extreme temperatures, as the hydraulic fluid changes its viscosity.
Professional maintenance is required for the tailgate to function reliably. The Volvo S60 tailgate mechanisms require regular lubrication of the hinges and inspection of the hydraulic cylinders every 30,000 km. A professional inspection of the electrical connections and timely replacement of worn seals can prevent expensive repairs and ensure optimal function.
The Volvo S60's gas cap often sticks or won't pop open, which can be particularly frustrating at gas stations. These faults typically occur between 50,000 and 80,000 km, with vehicles in salty winter areas being affected earlier. The locking mechanism wears out through frequent use and exposure to the elements, while corrosion blocks the moving parts. On 2004 models, a design flaw in the spring mechanism has been documented, leading to premature failure. The reliability of the system suffers particularly under extreme temperature fluctuations, which cause the metal to expand and contract.
A professional inspection is important for trouble-free operation of the fuel filler cap. The Volvo S60 fuel cap mechanisms require regular cleaning and lubrication with acid-free grease every 20,000 km. Preventive treatment with rust protection and timely replacement of worn springs can significantly extend the service life and prevent unexpected failures.
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BOSCH Throttle position sensor
Article number: 0 280 122 001
£27.49price incl. 20% VAT, excl. delivery costs
Article number: VE18320
More
£31.99
£31.99
for 1 litre
price incl. 20% VAT, excl. delivery costs
BREMBO Brake disc
320x20mm, 5, internally vented
Article number: 09.C938.11
£52.49
Price per item
£104.98 / Price per 2 items
price incl. 20% VAT, excl. delivery costs
Article number: KP15686XS-1
£175.49price incl. 20% VAT, free delivery
BLUE PRINT Oil filter
Spin-on Filter
Article number: ADM52122
£7.59price incl. 20% VAT, excl. delivery costs
The engine control unit of the Volvo S60 shows complex electronic faults, especially in the T5 and D5 units. The vehicle does not start or idles unevenly, accompanied by error codes in the diagnostic system. These symptoms mainly manifest themselves between 90,000 and 130,000 km, although an early problem phase can already occur around 30,000 km in intensively used vehicles. The weak points lie in the fuel injection sensors, which fail due to contamination or electrical faults. In the 2.4 petrol 170 hp models, problems with the ignition coil control have also been documented, leading to misfiring and reduced performance.
A systematic check is fundamental for optimum engine performance. The Volvo S60 engine control units require regular software updates and sensor calibration every 40,000 km by authorized workshops. Professional diagnosis with Volvo-specific diagnostic equipment can identify intermittent faults and ensure the longevity of the complex control system.
Based on the experiences of Volvo S60 drivers, the following additional problems occur:
| Strengths | Weak points |
|---|---|
| High passive safety | Automatic transmission problems |
| Solid body quality | Air conditioning failures |
| Comfortable suspension tuning | Electric tailgate defects |
| Strong engine performance with T5/D5 | Fuel filler cap mechanism |
| Good long-distance characteristics | Complex electronic faults |
| Stable diesel engines | High repair costs |
| Sophisticated interior concept | Wear and tear on comfort functions |
The Volvo S60 presents itself as a fundamentally well-designed vehicle with high safety standards, but one that requires regular and expert maintenance. The most frequent problems are concentrated on electronic systems and comfort functions, while the basic mechanical components have a good service life. A preventive maintenance strategy and timely intervention at the first symptoms can significantly improve reliability and control operating costs.
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