Two problems related to engine exhaust system have been reported for the 2004 Volvo S60. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Volvo S60 based on all problems reported for the 2004 S60.
It was a wet day, when I was driving I started to hear a loud screeching coming from underneith the car, it went on for a few minutes and would then go away, it would come back every few minutes. I took it into the Volvo shop and they told me they had a recall for it, but it was not for my VIN, they said it was from the metal contracting and rubbing against a moving part, because the repair was so expensive I had to wait, I was later driving on anouther wet day and got pulled over by the police because the noise was so loud. I informed him about what I was told and he recommended filing a report on this site.
The contact owns a 2004 Volvo S60. The contact stated that while driving in wet conditions at approximately 50 mph, with all wheel drive engaged, the exhaust system would expand, causing it to rub against the drivetrain. The failure caused a loud noise underneath the vehicle. The contact took the vehicle to an authorized dealership to have an exhaust bracket applied. The contact felt that the manufacturer should have been responsible for the repair expenses as it was unsafe to have moving objects rubbing against each other. The failure mileage was approximately 70,000.