The 2009 S40 is a compact Volvo with Ford influence in its platform years. The 2.5T turbo five-cylinder is the desirable engine, but automatic transmission cooling failures and PCV system issues plague these cars, often leading to expensive cascading damage if ignored.
Transmission Oil Cooler Failure Leading to Transmission Damage
Common · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Pink milkshake fluid in transmission dipstick or expansion tank (coolant mixing with ATF), Transmission slipping, harsh shifts, or limp mode, Overheating transmission temp warnings on dash, Coolant level dropping without visible external leaks
Fix: The internal transmission oil cooler inside the radiator fails, allowing coolant and ATF to cross-contaminate. Requires immediate flush of both systems, new radiator, and if caught late, full transmission rebuild or replacement. Prevention: replace radiator proactively at 100k. Repair: 8-12 hours for trans R&R and rebuild if damaged.
Estimated cost: $3,500-6,500
PCV System Clogging and Oil Sludge (Turbo Models)
Common · high severity
Typical onset: 60,000-100,000 mi
Symptoms: Excessive oil consumption (1 qt per 1,000 mi or worse), White smoke from exhaust on startup, Oil in intake tract and intercooler, Check engine light with multiple misfires, Rough idle and loss of power
Fix: The PCV breather box on the back of the block clogs with sludge, causing crankcase pressure to force oil past rings and valve seals. If ignored, leads to piston ring damage requiring engine rebuild. Fix involves replacing entire PCV system including breather box and oil trap, plus cleaning intake. If caught early: 3-4 hours. If rings are damaged: 18-25 hours for short block or engine rebuild.
Angle Gear and Rear Driveshaft Issues (AWD Models)
Occasional · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Clunking or grinding from rear differential area during acceleration, Vibration at highway speeds, AWD warning light illuminated, Metal shavings in angle gear fluid
Fix: The angle gear (transfer case mounted to transmission) develops bearing noise or seal leaks. Rear driveshaft carrier bearing also fails commonly. Angle gear replacement: 5-7 hours. Driveshaft carrier bearing: 2-3 hours. Often both are done together on higher mileage examples.
Estimated cost: $1,800-3,200
Power Steering Hose Leaks and Pump Failure
Common · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Power steering fluid puddles under car (front driver side typically), Whining noise from power steering pump, Heavy steering especially when cold, Low PS fluid warning on dash
Fix: High-pressure power steering hoses develop leaks at crimped ends, and the pump itself can fail from running low on fluid. Subject to recall for certain hose connections. Hose replacement: 2-3 hours due to tight access. Pump replacement adds another 1.5 hours if also needed.
Estimated cost: $600-1,200
Front Control Arm Bushings and Ball Joints
Common · low severity
Typical onset: 70,000-120,000 mi
Symptoms: Clunking over bumps from front suspension, Wandering steering or vague feel, Uneven tire wear on inside edges, Alignment won't hold settings
Fix: Front lower control arm bushings crack and ball joints develop play. Volvo sells complete control arms only (no serviceable bushings). Both sides typically done together with alignment. 3-4 hours total plus alignment.
Estimated cost: $800-1,400
Throttle Body Carbon Buildup and Idle Issues
Occasional · low severity
Typical onset: 80,000-150,000 mi
Symptoms: Rough idle or hunting idle when warm, Hesitation or stumble on light throttle, Check engine light with throttle position codes, Stalling when coming to a stop
Fix: Electronic throttle body accumulates carbon on the butterfly valve causing erratic idle. Requires removal, cleaning, and ECM relearn procedure. Some cases need new throttle body if motor is worn. 1.5-2 hours labor.
Estimated cost: $250-600
Owner tips
Change transmission fluid every 40k miles and inspect for pink discoloration—catching cooler failure early saves the transmission
Service PCV system at 60k intervals on turbo engines—replace breather box and oil trap together
Use quality full-synthetic oil (0W-30 or 5W-30) and change every 5k miles to prevent sludge
Inspect power steering hoses annually for seepage—crimped ends fail first
If buying used, verify transmission has no shudder and engine doesn't smoke—these are expensive to fix
Buy the turbo with a manual transmission if you can find one and verify PCV system maintenance; avoid high-mileage automatics unless transmission and radiator have been recently replaced.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
Fitment notes: H6 group also fits; battery located under hood on driver side
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Every control module on the 2005-2011 Volvo S40 — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
Power Steering Control Module (PSCM)2.0 hr R&Rdealer / factory tool +0.5 hr▸ programming details
📍 Steering column area or integrated with electric power steering motor
🔧 VIDA/DiCE
⚠️ Electric power steering only (not all models); calibration required after replacement; 2008+ models
📍 Integrated with CEM or separate module near ignition switch
🔧 VIDA/DiCE
⚠️ Key programming required; all keys must be present; typically integrated with CEM on this generation
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
VOLVO IS RECALLING CERTAIN PASSENGER VEHICLES EQUIPPED WITH POWER FRONT PASSENGER SEATS. THE FRONT SEAT RAIL'S DETECTION SYSTEM WAS MANUFACTURED INCORRECTLY AND MAY PERMIT THE PASSENGER TO FORWARD THE SEAT BEYOND THE INTENDED MAXIMUM.
Consequence: POSITIONING OF THE SEAT BEYOND THE INTENDED MAXIMUM CAN CAUSE INCREASED RISK OF INJURY TO THE PASSENGER IN THE EVENT OF A CRASH.
Remedy: DEALERS WILL INSPECT THE FRONT POWER SEAT STOPS FOR BOTH FRONT SEATS FOR THE PRESENCE OF AN "END STOP" AND REPAIR THE VEHICLES AS NECESSARY FREE OF CHARGE. THE SAFETY RECALL BEGAN ON DECEMBER 23, 2010. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552 OR AT [email protected].
VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Consequence: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Remedy: VOLVO ADVISES OWNERS TO PLEASE STOP USING THE GARMIN PORTABLE GPS DEVICE IMMEDIATELY, AND VISIT THE GARMIN WEBSITE TO DETERMINE IF THEIR UNIT IS AFFECTED. THE UNIT'S BATTERY WILL BE REPLACED WITH A NEW BATTERY AND A SPACER WILL BE INSERTED ON TOP OF THE BATTERY NEXT TO THE PCB. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 18, 2010. OWNERS MAY CONTACT GARMIN AT 866-957-1981 OR VISIT GARMIN'S WEBSITE AT WWW.GARMIN.COM/NUVIBATTERYPCBRECALL.
STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS · 08V329000
2008-07-23
VOLVO IS RECALLING MY 2008-2009 VEHICLES. A SECTION OF THE POWER STEERING RETURN LINE HOSE WAS NOT PROPERLY VULCANIZED (CURED) AND DOES NOT MEET SPECIFICATIONS. IF THE POWER STEERING RETURN HOSE FAILS, A SUDDEN RUPTURE OF THE HOSE CAN OCCUR.
Consequence: THIS CAN RESULT IN A RAPID DRAINAGE OF THE POWER STEERING FLUID IN THE SYSTEM AND A COMPLETE LOSS OF POWER ASSISTANCE, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT AND REPLACE THE STEERING RETURN LINE HOSE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 13, 2008. OWNERS MAY CONTACT VOLVO AT 1-800-458-1552.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2009 Volvo S40 2.4L I5 and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.