Model Reports 4 min read Updated 18 Oct 2026

Volvo S40 2004: reliability & common MOT faults

In 2025, 54 in every 100 first MOTs on a 2004 Volvo S40 were passes. Most common reason for a fail: Drive shaft joints and boots (front).

Summary

With 861 first tests, there are too few to say whether the 2004 Volvo S40 differs from the model years either side.

At a glance

How 861 first tests went in 2025.

Passed first time
54 in every 100
Did not pass first time
46 in every 100395 failed first-attempt tests
The typical car
21 yearsabout 98,930 miles
First tests counted
861

What failed most often

  1. Drive shaft joints and boots (front)15 in every 100 failed tests
  2. Handbrake efficiency below minimum (roller test)15 in every 100 failed tests

How we count this. Data: UK MOT open data, 2025. Only Class 4 cars on their first MOT of the year are counted. A car that fails and is fixed at the test station still counts as a fail in the first-attempt rate. These are raw results, not adjusted for age, mileage, or peer mix. The MOT does not test engine or gearbox internals.

Note:

These are patterns across 2004 Volvo S40 vehicles in 2025, not a prediction that any one car will have them. Faults are grouped by part of the car. They come from MOT defect codes, not manufacturer bulletins, recalls or a diagnosis of any one car.

Steering

One fault: steering rack (front), 4.6 times as often as on similar cars.

Figures below are measured across the 395 failed first attempts in 2025 that had a mileage recorded, which allows a like-for-like comparison.

We only list faults with at least 20 failures and a rate of about 2.0 times that of similar cars, which keeps one-off results out of the list.

Steering rack (front)

Failed on 21 first tests4.6 times as often as similar carsPossible evidence

What it means

Steering gear casing retaining devices dangerously loose, or visible relative movement to the chassis or bodywork, is graded Dangerous. A casing not properly attached, or fractured, is Major, but a fracture that affects the stability or attachment of the casing is Dangerous. A gaiter damaged but still keeping dirt out is Minor, and Major once missing or no longer doing so.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Suspension

One fault: coil spring (rear), 3.7 times as often as on similar cars.

Coil spring (rear)

Failed on 37 first tests3.7 times as often as similar carsLikely evidence

What it means

A missing bump stop rubber is not a reason to fail a coil spring. When the vehicle is jacked and lowered, a spring that does not correctly locate as the suspension returns to its normal running position is rejected as insecurely attached. A missing spring is Major, and graded Dangerous where directional control is affected.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Seat belts and restraints

One fault: airbag warning light, 2.8 times as often as on similar cars.

Airbag warning light

Failed on 36 first tests2.8 times as often as similar carsPossible evidence

What it means

The airbag warning lamp (SRS MIL in DVSA's wording) is failed only if it indicates a system malfunction, which is Major. A lamp lit to show the passenger airbag is disabled is not to be regarded as a defect. Dashboard messages are not a defect in their own right, though they can help the tester confirm a malfunction.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Body and structure

One fault: drive shaft joints and boots (front), 2.4 times as often as on similar cars.

Drive shaft joints and boots (front)

Failed on 59 first tests2.4 times as often as similar carsPossible evidence

What it means

A constant velocity boot that is only severely deteriorated is Minor. It is Major once it is missing, split or insecure so that it no longer prevents the ingress of dirt. A transmission joint excessively worn is Major, and graded Dangerous when it is so worn it is likely to fail.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Advisories

Other things testers noted as worn or close to failing, more often than on similar cars.

An advisory is a note from the tester about something that has not failed yet. It is an early warning, not a fail.

Brake pads (rear)

Noted on 27 first tests2.3 times as often as similar carsWear pattern

Brake discs (rear)

Noted on 56 first tests2.2 times as often as similar carsWear pattern

Data: UK MOT open data, 2025. Counts cover advisories recorded on failed first tests only, compared with cars of the same age and mileage.

MOT pass rates

How first tests ended, and how the pass rates are counted.

Passed first time
54in every 100
Passed on the first test.
Fixed at the station
9in every 100
Failed, then fixed at the test station the same day.
Failed
37in every 100
Did not pass, and were not fixed at the test station.

First-attempt pass 54.1% of 861 first tests (2025): only cars that passed first time count. Official-style pass 62.6%: cars fixed at the test station also count as a pass. The 9 fixed and the 37 not fixed make the 46 in every 100 that did not pass first time.

Same model, other years

Passed first time in every 100, all tested in 2025.

40608010020042010Older carsNewer cars
40608010020042010Newer cars

Newer cars are younger, so look for a jump rather than the climb. A year earlier (2024), when these cars were a year younger, 52 in every 100 passed first time.

YearPassed first timeFirst tests
200252 in every 100327
200352 in every 100501
2004 This car54 in every 100861
200557 in every 1001,084
200660 in every 1001,279
200758 in every 1001,449
200858 in every 1002,347
200957 in every 1002,017
201058 in every 1001,630
201157 in every 1001,289
201259 in every 1001,176

FAQs

Short answers about how to read this model-year guide.

With 861 first tests, there are too few to say whether the 2004 Volvo S40 differs from the model years either side. Its main cause of failure was Drive shaft joints and boots (front), about 15 in every 100 failed tests. In 2025, 54.1% of 861 first MOTs on the 2004 Volvo S40 passed first time (PRS: items fixed at the station the same day, counted as a fail). The official-style rate including PRS is 62.6%. Among 395 failed first-attempt MOT tests (test year 2025), Steering rack (front) appears more often than on similar cars (5.3% of those tests; 21 observed failures; about 4.6× more often than similar cars). There is no single reliability score here; this is a pre-purchase checklist built from DVSA open data, not a guarantee for any individual car.
Ranked by how often they were actually recorded, the items that most often failed a 2004 Volvo S40 at the first attempt were Drive shaft joints and boots (front) (14.9%) and Handbrake efficiency below minimum (roller test) (14.7%), each as a share of the year's failed first attempts. That is what goes wrong most often on the car. The common faults table shows a different measure: faults that are unusual compared with similar cars.
Among failed first-attempt tests we highlight patterns that appear more often than on similar cars. Top example: Steering rack (front) (5.3% of those tests; 21 observed failures; about 4.6× more often than similar cars). These are statistical signals, not a diagnosis of any individual car.
Steering rack (front) shows up more often than on similar cars (5.3% of those tests; 21 observed failures; about 4.6× more often than similar cars). That does not prove a design fault. Age, mileage, and how the car was used still matter. Treat it as a pre-purchase checkpoint, not a manufacturer service bulletin.
Common MOT problem areas for the 2004 Volvo S40 include Steering rack (front), Coil spring (rear), Airbag warning light. These are the faults that stand out compared with similar cars, not a complete list of what can go wrong on any individual car.
Advisories flag issues noted at the test and are not a fail rate. We show advisory patterns that appear more often than on similar cars among failed first-attempt tests, separate from common failure rows. Use them as early-warning checks, not as a pass/fail score.
This page highlights MOT failure patterns for the 2004 Volvo S40 (registration year) using UK DVSA open data for the selected test year. Patterns are compared with cars of a similar age and mileage. It is a buyer checklist from MOT defect statistics, not a full service history or manufacturer service-bulletin list.
No. MOT tests do not cover engine internals, gearboxes, or many electronic modules. Patterns here come from MOT defect statistics only and should not be read as engine or gearbox reliability scores.

About this data

How this page is built and what it can (and can't) say.

These figures come from UK MOT open data for this model year. We surface common failure patterns against similar cars, not a full reliability score, and not a pass/fail verdict on any individual vehicle.

2024 2025

What we include

UK Class 4 cars only. Normal MOT tests (not retests); first test per vehicle per calendar year; results pass, PRS, or fail.

Same-day repairs

PRS means the car failed items that were fixed at the test station and then passed the same day. We count PRS as a first-attempt fail in headline rates so same-day repairs do not hide problems.

How we compare

We compare this model year with other Class 4 cars of similar age and mileage in the same test year. This model family is left out of the peer group so the car is not measured against itself.

What this does not cover

  • MOTs do not cover engine internals, gearboxes, or many electronics; this is not a full reliability score.
  • Common faults come from MOT defect stats, not manufacturer TSBs or recalls.
  • Age and mileage matching reduces, but does not remove, differences in how cars were used and maintained.
  • If the data for a car is too thin to say anything useful, we say so rather than guess.

Contains public sector information licensed under the Open Government Licence v3.0.

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