Two problems related to brake disc pads have been reported for the 2002 Volvo S40. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Volvo S40 based on all problems reported for the 2002 S40.
Types of recurring issues with Volvo S40: headlights, driver front window motor, early brake pad wear. Headlight bulbs were replaced 2-3 times a year at consumer's cost. When brought to the attention of Volvo dealer they reported that it was probably due to lights being used during daylight. They check electrical and reported no issue. Had brake pad and rotor issued shortly after purchasing the vehicle. Volvo dealer reported Volvo rotors were built thin and soft. Cost of brake replacement was not covered under warranty as it was considered regular wear. Driver side window regulator has been replaced three times. First regulator was replaced in June 2005, then February 2006 and now may 2007. May 2007 regulator was at the cost of the consumer as warranty had expired and warranty on part only lasts 12 months even though there is an apparent problem.
The rear brake pads on my 2002 S40 Volvo wore out at about 21 thousand miles and ruined the rotor. According to Volvo corp. This is becasue the government is has prohibited them from using asbestos in the brake pads. Volvo put noise making "squealeres" on the inside pads but due to the design of the brakes the outside pads wear out first causing a rivit on the pad to contact the rotor and ruin it before the pads can be replaced. According to three Volvo service managers it is normal for the pads to wearout at between 15 and 20,000 miles. I have contacted Volvo of America by email on two occasions to advise them of the obvious problem with their brakes they advised me they could offer me no reimbursement for the premature brake failure and would file the information .