2004 Volvo S40 — MOT failures & pass rate
Across 9,821 MOT tests, the 2004 Volvo S40 recorded a 70.3% pass rate. That is 1.6 percentage points worse than small family cars of a similar age, which fail at 28.0%. Failures cluster in lighting & signalling, suspension and brakes.
What the MOT record shows
Lighting & signalling dominates the failure mix at 16.8% of all tests — 3.6 points clear of suspension, so it is the first thing to check.
At component level the recurring items are position lamp, headlamp aim and joints — position lamp alone was recorded 669 times.
A 150k+ example is materially riskier than a 0-30k one: 32.2% versus 6.9%.
Split by fuel, diesel examples fail 2.7pp more often than petrol ones (31.7% vs 28.9%) — worth weighing if you have a choice.
Advisories point at the next bill rather than this one: brakes was flagged on 32.2% of tests without failing them.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 16.8% | 1,651 |
| 2 | Suspension | 13.3% | 1,301 |
| 3 | Brakes | 12.8% | 1,259 |
| 4 | Body, structure & corrosion | 7.4% | 731 |
| 5 | Tyres | 6.2% | 608 |
| 6 | Emissions & environmental | 5.2% | 508 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Position lamp | 669 |
| 2 | Headlamp aim | 655 |
| 3 | Joints | 625 |
| 4 | Coil spring | 569 |
| 5 | Rbt (sp) | 560 |
| 6 | Rigid brake pipes | 349 |
Top advisory categories
Advisories aren't failures, but they flag work likely needed soon — useful when budgeting.
| # | Category | % of tests with advisory | Tests |
|---|---|---|---|
| 1 | Brakes | 32.2% | 3,165 |
| 2 | Suspension | 29.9% | 2,941 |
| 3 | Tyres | 27.7% | 2,718 |
| 4 | Lighting & signalling | 17.4% | 1,711 |
| 5 | Body, structure & corrosion | 13.9% | 1,368 |
| 6 | Other defects | 12.4% | 1,217 |
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 | 58 | 6.9% |
| 30-60k | 1,098 | 23.6% |
| 60-90k | 2,635 | 28.4% |
| 90-120k | 2,738 | 30.8% |
| 120-150k | 1,856 | 32.0% |
| 150k+ | 1,430 | 32.2% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 7,250 | 28.9% |
| Diesel | 2,570 | 31.7% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 2,796 | 29.6% |
| 2022 | 2,368 | 30.1% |
| 2023 | 1,938 | 29.8% |
| 2024 | 1,543 | 29.9% |
| 2025 | 1,176 | 28.3% |
What to check before buying a 2004 S40
On a 2004 S40, lighting & signalling is what the MOT record says goes wrong most — it appeared in 16.8% of tests. Check these areas before you commit.
- Lighting & signalling (16.8% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (13.3% 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.
- Brakes (12.8% 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.
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 S40s pass their MOT?
70.3% of the 9,821 2004 Volvo S40 MOT tests in this dataset passed — a 29.7% fail rate.
What is the most common MOT failure on a 2004 Volvo S40?
Lighting & signalling, recorded in 16.8% of tests, followed by suspension (13.3%).
Does the 2004 S40 get worse with mileage?
Its MOT fail rate rises from 6.9% in the 0-30k band to 32.2% in the 150k+ band.
Methodology & source. Based on 9,821 MOT tests. Dataset: DVSA MOT testing data (2021,2022,2023,2024,2025). Data last updated 2026-07-27. Figures reflect MOT-testable defects only — read the methodology for how these are calculated and what they don't measure.