Rear Suspension Coil Springs Problems of Volvo S40

While driving the right front and right rear coil springs broke and the front coil spring damaged the tire. Dealer stocks these expensive springs (both front and rear) in larger than normal amounts due to incidences of breakage. I feel that this was an early failure for this type and age of vehicle and should it have been a a higher speed the incident could have been severe.

See all problems of the 2002 Volvo S40 🔎.

On 3/4/2009, while doing other work to the car, a mechanic discovered that the rear passenger side coil spring was broken. It was broken at the lowest point and the car still sat level, so I was not even aware. I do not know how long it was broken. It looked like it just deteriorated over time. Although over 9 years old, the car has less than 64,000 mile, so I would not expect a coil spring to deteriorate like that. The dealer replaced both rear coil springs for $773.

See all problems of the 2000 Volvo S40 🔎.

1. Events = regular tire rotation in September 2008. Technician pointed out to me the corrosion and crack/failure in both rear coil springs. Mileage on the vehicle about 68,000 at time of discovery on my 2000 Volvo S40. 2. Corroded and cracked rear coil springs (both). The corrosion and crack were almost in the same location with the same amount of corrosion near the bottom (the first half-moon curve) of both springs where they are seated/braced. 3. October 2008 - took vehicle to local Volvo dealer for evaluation. They ordered new rear coil springs. I returned a week later to have the new coil springs installed at the cost of approximately $550, plus alignment. The cost of the coil springs was approximately $220 for both. The remainder was labor. I wrote a letter to Volvo of north America about this condition. I included photos, and I requested a refund. Volvo customer service of north America called me on November 6, 2008, and denied my request. I was told that my car was out of warranty, and the engineers described the problem as an "anomaly," not a defect. Since I have a low mileage vehicle, I live in a "salt state," and certain saabs in salt states are being investigated for front coil spring failure, it would be interesting to know whether there is a connection with these vehicles and the rear coil springs. I have loaned the failed rear coil springs to a professor of automotive engineering to use in his upper level design class to use as an example of a failure. I could likely get the parts back, if needed.

The contact owns a 2000 Volvo S40. The contact heard a loud, unfamiliar noise while driving. He discovered that the rear coil springs had failed on both the driver and passenger sides of the vehicle. He took the vehicle to the dealer and they stated that it was unusual for both springs to fail simultaneously. The dealer did not state whether or not the vehicle was related to any recall(s) based on his VIN. The current mileage is 130,000 and failure mileage was 128,000.