Five problems related to automatic transmission have been reported for the 2002 Volvo S60.
2002 Volvo S60 - transmission clunks when engaging gear in drive. Problem is most noticeable when shifting from reverse. Hesitation to engagement can be up to 2 seconds, then engages very harshly producing the "clunking". Was told a software flash may correct issue but I am reluctant to spend $80 to discover it did not work. Vehicle started demonstrating problem at 80k miles when manually downshifting to first gear to come to a stop. Now has 114k miles and driven very carefully with foot hard on brake when shifting from reverse to drive. I no longer perform any sort of manual shifting when in forward motion.
We are a 2 Volvo family (having purchased them "pre-certified from Volvo 2 and 3 years ago respectively). Both cars (2002 S60 & 2001 cross country) have had to have their transmissions replaced since purchase - mine once (so far) and my husband's three times - all before 55,000 miles. I went online and found literally hundreds of complaints on defective Volvo transmissions: all Volvo models - from 2001 through 2006 and mileage ranging from 20,000 to 60,000. Why has Volvo USA not been taken to task on these defective factory installed transmissions and made to stand behind the manufacture of their cars?.
The angel gear failed (also known as the bevel gear) causing a loss of the awd system. Symptoms include excessive torque steer and excessive front wheel spin. >$2300 repair. Dealer indicated that there was no specific reason for the failure and that there was no preventive maintenance on this part.
I have had many problems with the transmission, car will stall in traffic, car would not start at all. This car has been in service many many times. The problems persist. I have sent 9 emails to their head quarters since 12/5, no reply.
While driving my Volvo 2002 S60 awd I experience what is referred to as an engine flare. While car shifts automatically from gear to gear the engine will race and the tachometer needle will jump. The car will lurch forward once the gear finally catches. This can happen when the car is cold or hot. It can occur at anytime and any gear. It has also happened while stepping on the brake. I have been experiencing this problem since Feb. 2002 and Volvo still has yet to fix it. I have made numerous calls to Volvo n. A. And the dealer vovloville of massapequa, NY. The dealer tells me that they are still waiting to hear from Volvo n. A. And Volvo n. A. Continues to tell me that they are looking into it but they never call me back with any information.