This is a Technical Journal: When sensitive information, like vehicle speed, brake usage, etc. (customer behavoiur information) of a car is required from Volvo Car Corporation from external sources, either of these two documents should be filled in and attached to the affected Vehicle Report. (External sources: Authority, Insurance companies, Rental companies, etc)
full bulletin at NHTSA ↗2005 Volvo S40 brakes problems
moderate 8 complaints filed with NHTSA · avg repair $450 · see brakes across all vehicles →
Complaints
8
Recalls
0
Avg fix
$450
What stands out
No new NHTSA brakes complaint has been filed on this vehicle in over 21 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering brakes on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This is a Technical Journal: When sensitive information, like vehicle speed, brake usage, etc. (customer behavoiur information) of a car is required from Volvo Car Corporation from external sources, either of these two documents should be filled in and attached to the affected Vehicle Report. (External sources: Authority, Insurance companies, Rental companies, etc)
full bulletin at NHTSA ↗VOLVO: THE ABS LIGHT IS ON WITH FOUR POSSIBLE TORUBLE CODES.
full bulletin at NHTSA ↗VOLVO: UNNECESSARY BRAKE CONTROL MODULE (BCM) REPLACEMENTS. WHEN DIAGNOSING DIAGNOSTIC TROUBLE CODES (DTC'S) FOR BRAKE CONTROL SYSTEM, TECHNICIAN MUST ALWAYS FOLLOW COMPLETE DIAGNOSTIC FAULT TRACING PATH IN VIDA. VIDA ALWAYS LISTS POSSIBLE SOURCES OF FAULT.
full bulletin at NHTSA ↗VOLVO: ANTI SKID SERVICE REQUIRED MESSAGE, SWM-0201, BCM-0109, EPS-0080. NEW SWM SOFTWARE HAS BEEN IMPLEMENTED INTO PRODUCTION AFTER THE CHASSIS RANGE IN THE HEADER.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
What owners are reporting 2 most recent
The consumer stated that the distance between the brake pedal and the tunnel was 5.1 inches which did not leave enough room for his foot to maneuver. The consumer felt that this was a design defect. *ak (Volvo s40 2005) *sc *jb
Three attempts have been made so far to correct a brake problem. We are currently working on having the car services a fourth time in the course of 6 months, my car has been in the shop a total of three weeks. *nm
Had brakes trouble with your 2005 Volvo S40?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the brakes problem on the 2005 Volvo S40?
It's a documented issue but not catastrophic. 8 complaints have been filed. Repairs average $450 and most owners catch it before it causes a breakdown.
At what mileage does the brakes typically fail?
Based on the 8 complaints filed, brakes issues most often appear around 58,500 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $450 for brakes repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to brakes?
No active recalls currently cover brakes issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Volvo/S40.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.