2000 V40 Problem list:
(1) Plastic center cap fell out of one wheel. Replaced on warranty with the newer kind with a spring clip.
(2) One headlight bulb burned out at about 21,000 miles.
Not bad for 2 1/2 years.

My 2001 V40 should have been painted yellow, its a lemon, soon to be replaced (not with another Volvo!)
In 90,000 KM, two sets of tires due to out of spec alignement, insufficient caster on left front, real bad camber and toe on left rear. can not be aligned to spec. Volvo non responsive.Scary handling in icy conditions, bad rear wheel bump steer.
SRS warning light came on twice, rear wiring harness replaced twice.
Front seat belts cut into B pillar trim and frayed edge of belt. Changed under warrenty, doing it again.
Rear brakes every 15-20K.Fronts and all rotors at 24K
Bad shift characteristics, re-programed, no better.
Speed sensor failed, no warrenty, Service manager claims "speed sensor not related to on going, repeat complaint of transmission problems, as the speed sensor has nothing to do with transmission" It's little wonder servicing is poor when the SM is obviously technically incompetent.
Noise from steering, no fault found.
Spark plugs every 20K.
Fuel mileage nowhere near Volvo's claims.
Rear strut isolators,warrenty
Headlight bulbs x 6, service bulletin to install resistors has cured problem.
A/C evaporator, leaks condensate onto passenger floor, replaced under warrenty, ensuing dash rattles not yet found.
Spare tire cover warped like a banana, warrenty denied.
Light bulbs for in dash switches failed, parts back ordered for 3 weeks! these clowns cannot even stock light bulbs!

In 21 months of ownership, this piece of crap has been in the shop, awaiting back-ordered parts for a total of over eight weeks.

Problem list V40 2001:
oxygen sensor #1 defective at 8k mls, replaced warranty
oxygen sensor #2 defective at 9200 mls, replaced warranty
brakes squealing and grinding at 12k mls, replaced pads warranty, still good at 45k mls
driver window squealing at 20k mls in hot weather, never fixed well
H7 bulbs both burned out 1/yr, warranty
steering wheel coating comes off at 40k mls, out of warranty
no-start condition twice at about 28k mls, waited two weeks for camshaft position sensor shield, loaner car, warranty
transmission false neutral when upshifting problem at 40k mls, so far nothing but excuses and 5 days in the shop, loaner, warranty
driver seat frame rattling, replaced, warranty, 25k mls
brake vacuum pump died, no warning light, just no power brakes, nearly crashed the car because of it, warranty, 40k mls

To sum it up: most fun-to-drive car I ever had, most problem plagued car I ever had; don't plan on another Volvo once my lease is up
gerat car if you need socializing with the service department....

I also have had a few problems since I bought my 2000 S40 last year. This is the first Volvo product I have ever owned and it was purchased from a local Volvo dealership. (Purchased Used)

My thrills started when they check engine light came on within the first 24 hours of ownership. I brought the car back to get that fixed along with a noise that was coming from the front end. Over the first 30 days of my ownership the car spent 21 days at the dealership getting repaired. The Volvo retailer did give me a loaner car over this period and tried to make me feel better about the purchase. Did I buy a Certified Car that was a Certified Lemmon? After reading these posts, my problems are the same as everyone else. I was able to obtain the service records from day one and they are as follows:

13,001 Miles - Rear brake pads are bad and brake light is on; Replaced three center wheel caps;

14,859 Miles - Check Engine Light is on; Replaced Left and Right headlights;

20,258 Mikes - Check Engine Light is on; Replace front brake pads;

24,833 Miles - Extreme Vibration from engine. Front engine mount needs replaced;
Replace three center wheel caps;

In April 2002,I purchaed this car as a Certified Used Car with 24,875 miles on it.

24,920 Miles - Check Engine Light is on; Extreme Vibration from Engine;
Left front axle nut needs retorquing; Recall 109;

25,147 Miles - Check Engine Light is on & arrow is flashing; Customer to
return with SOP Arrives;

25,279 Miles - PNP Switch Replaced;

I have since had the front sway bar replaced, a relay switch replaced, and another set of headlights (left & right). Currently, the car has about 33,000 miles. I would trade in the car but I am very upside down.

Regards,

Mike - Houston, TX

I have a 2000 S40 1.9T with only 19k miles. Whoever engineered this car should be shot! The car is a joke! Here are the problems I've had and got fixed:

-Engine mount replaced
-Bulbs replaced twice already
-Some sway bar work done
-2 Power Steering Failures
-Clunking problem when pulling from idle front driver side
-rear brakes needs replacement already
-2 oil leaks already, replaced oil pan gasket and another seal somewhere
under the car

My goodness! This is the worst car I've owned! I can feel it wear down on me already. I thought I made a car class upgrade from Toyota to Volvo. I may downgrade back to Toyota. Did I also mention the paint is just poor quality and
the car's throttle response is terrible. I'm at the point now to go talk to the general manager at the dealer for a replacement. Has anybody here done this?

2000 S40 with 61000 miles.

I have lost track of the number of headlight bulbs I have replaced.

Rear brakes every 20,000 miles, I replace them myself. Front Pads lasted 40,000 miles, tried a set of EBC Green Stuff pads that were supposed to by low dust. They were dirtier than the originals and did not last 20,000 miles. This time I have the Mintex pads on the front, they are much cleaner.

Had to have the coolant temp sensor and thermostat replaced at 60,000. Vacuum pump sticks and runs continuously, dealer says nothing is wrong!

Noise in the front end when pulling away from a stop in cold weather.

Had to replace a front sway bar mount, that was a real bitch!

It just seems to me that there have been too many issues for something a little better than a Ford, GM, etc.

Considered trading it in and most dealers were only willing to give about 7-8,000 trade. I thought these cars held their value better than that.

Both the wife and I like the car, but I starting to get scared about the potential for astronomical repair bills as it gets older....and the dealer is about 130 miles away.

Tony D

Had it for 2.5 yrs., 12 days in the shop for non-Maintenance repairs, now transmission problems at 40k mls, did not start twice, had to tow, light on more often than low fuel lamp.
A hoot to drive, but a sad joke of engineering with 5 yrs of build experience on this model by the time I bought it.
My conclusion: first Volvo will be last Volvo, since FORD took over for sure (remember those 3.8L head gaskets and engine mounts etc.).
Too bad for Volvo that other companies can build fun-to-drive cars that come with next to none problems and are nearly the same $$ wise.

'00 S40 with 66k.........in the ist 15k I had a host of what I call unfortunate but minor problems all fixed under warranty or by myself. In no particular order..Check engine light,headlight burnouts,vaccuum fuse,shift-lock adjustment, seat-clicking,interior climate control light bulb,radio lights...I may have missed something but after approx 15k...all the problems were fixed except one...15k-30k more check-engine light fails finally fixed by more software downloads and a "Volvo Check-engine recall notice" that finally fixed it....knock on wood.......from 30-64k...NOTHING! At 65k both front wheel bearings went.........really weird, but both started buzzing at approx the same time. Thats it! I do have to give the positive side........my front brake pads have lasted an average of 25k, my rears 30k! I have not had to replace any rotors, suspension parts Oh Oh...yes I did, two tie rods! No muffler problems, no A/C, heating,cooling,alignment....? I love the car!!! It is as tight as when new, gets excellant,excellant gas milage....if driven economically!!!! I plan o keeping it at least 2 more years, and then I'll get my last Volvo....an S80 or however ford messes it up! (Sorry!!!....no I'am not sorry!!!!!!!!!!!!!!!!!!!) Somewhere in Essex Jct. Vermont, still trying to break 40 mpg @ 60 mph! Bill

I also had minor to major issues with my 2000 Volvo S40 1.9T. The list are as follows:

1) Fog lights kept on flickering. The cause was poor wiring. The fix was they had to rewire them so they will not clamp next to the body.
2) A/C unit was dripping water and misting. Cause not known but they decided to replace the condensors.
3) Car would not start. Cause was bad ignition unit. The fix was to replace the ignition unit.
4) Sunroof rattles. Cause was the the visor was loose. The fix was none. They could not reproduce it even though the head mechanic test drove the car with me and heard the same noise.
5)Rear breaks gone at 11,000 miles. The fix was had to replace them both. Front was already at 50% left.
6)When backing up a loud pitch squeel was heard. Cause was driver side brake pump was bad. Fix was replacing the bad brake pump.
7)Everytime I accelerate when the temperature was below 35 degree I could hear a grinding noise coming from the passenger side. Cause was the engine mount was faulty. Fix was replacing the engine mount.

I think the 2000 Volvo S40 was a bad year for the car since it was the first for US. Later model does not seem to have major issues like the ones I had. I only had 1 more year left on the warranty and decided not to chance it so I traded in the car for an Audi A4. Since Volvo has been discounting the S40 considerably the valuation of the S40 are extremely low. Only got $13,000.

My V40 00 with 42K miles has had a few issues.
Rear brakes at 25K, Front brakes at 41K. Fuel Pressure regulator replaced at 40K, Thermostat at 40K. Both previous items caused CHECK ENGINE light to stay on. Drivers door window lift motor replaced at 41K.
Otherwise its been a great vehicle. I love driving it, gets good MPG, very good in the snow.
Thanks,
Craig

2002 S40 up to 15,000mi. Zero problems in the year and a half we've owned the car.

mormit
--
85 245DL 'The World's Fastest Production Tank' 02 S40

The X40 is far from one of Volvos better cars but then most of todays newer Volvos aren't doing much better than that either. If you had a '99 S80 for example, the list would be at least twice as long.
I'd say your problems on one car aren't exactly typical but I've seen those with one exception, the "heat shield causing a no start"? Can't imagine what that's about.
Rear brake pads wear prematurely on X40s because they fit too tightly out of the box and with a little rust, corrosion sieze in the calipers and can't move back with the pedal depressed. As a result, they'll wear out quickly and 15K miles isn't unusual. That problem can be effectively cured by slighly grinding some material from both edges of each new brake pad, then using anti-sieze compound. The pads will then be able to move in the calipers freely w/o sticking.