2004 Volvo S60 — MOT failures & pass rate
Across 8,719 MOT tests analysed for the 2004 Volvo S60, the most common recorded failure areas were lighting & signalling, brakes and suspension. Its pass rate of 73.6% was in line with the average for cars of a similar age (74.2%). Higher-mileage examples failed more often — 28.9% in the 150k+ group versus 21.2% in the 0-30k group.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 19.9% | 1,736 |
| 2 | Brakes | 13.5% | 1,175 |
| 3 | Suspension | 8.5% | 737 |
| 4 | Tyres | 6.6% | 571 |
| 5 | Body, structure & corrosion | 4.5% | 396 |
| 6 | Visibility | 4.4% | 380 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Headlamp aim | 954 |
| 2 | Position lamp | 928 |
| 3 | Rbt (sp) | 701 |
| 4 | Headlamp | 466 |
| 5 | Pins and bushes | 418 |
| 6 | Parking brake performance | 291 |
Top advisory categories
Advisories aren't failures, but they flag work likely needed soon — useful when budgeting.
| # | Category | % of tests with advisory | Tests |
|---|---|---|---|
| 1 | Suspension | 31.1% | 2,708 |
| 2 | Tyres | 27.7% | 2,419 |
| 3 | Brakes | 24.7% | 2,152 |
| 4 | Lighting & signalling | 19.5% | 1,698 |
| 5 | Other defects | 14.1% | 1,233 |
| 6 | Body, structure & corrosion | 10.3% | 898 |
Failure rate by mileage
Higher-mileage cars tend to fail more — often the most useful guide to real condition.
| Mileage band | Tests | Fail rate |
|---|---|---|
| 0-30k | 33 | 21.2% |
| 30-60k | 305 | 19.7% |
| 60-90k | 1,057 | 20.9% |
| 90-120k | 1,847 | 25.7% |
| 120-150k | 2,039 | 26.6% |
| 150k+ | 3,408 | 28.9% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Diesel | 5,037 | 26.5% |
| Petrol | 3,678 | 26.1% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 2,423 | 26.7% |
| 2022 | 2,082 | 26.3% |
| 2023 | 1,712 | 25.6% |
| 2024 | 1,405 | 26.4% |
| 2025 | 1,097 | 26.9% |
What to check before buying a 2004 S60
Before buying a 2004 Volvo S60, focus on the areas it most often fails on. Lighting & signalling accounted for 19.9% of tests for this year.
- Lighting & signalling (19.9% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Brakes (13.5% of tests): Pads/discs are routine wear; binding, imbalance or corroded pipes are more serious — test for pulling under braking. Typical repair: £100–£350 per axle.
- Suspension (8.5% of tests): Worn drop links, bushes, springs or shocks — listen for knocks over bumps and check for uneven tyre wear. Typical repair: £150–£450 per corner.
Repair costs are rough UK ballpark ranges to set expectations, not quotes — actual prices vary widely by car, parts and garage.
Frequently asked questions
How many 2004 Volvo S60s pass their MOT?
73.6% of the 8,719 2004 Volvo S60 MOT tests in this dataset passed — a 26.4% fail rate.
What is the most common MOT failure on a 2004 Volvo S60?
Lighting & signalling, recorded in 19.9% of tests, followed by brakes (13.5%).
Does the 2004 S60 get worse with mileage?
Its MOT fail rate rises from 21.2% in the 0-30k band to 28.9% in the 150k+ band.
Methodology & source. Based on 8,719 MOT tests. Dataset: DVSA MOT testing data (2021,2022,2023,2024,2025). Data last updated 2026-07-01. Figures reflect MOT-testable defects only — read the methodology for how these are calculated and what they don't measure.