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2004 S60 R - Introduction, Current and Future Maintenance

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rolsen11
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Post by rolsen11 »

I made a post about it in the MVS Car Talk section, but I'll finally start posting here in the P2 section for the first time since I just bought a 2004 S60 R yesterday! I figure it would be nice to make a thread here to document my journey with this car alongside the community feedback I can get from all you knowledgeable people! My family and I have been Volvo enthusiasts for a long time but none of us have had a performance model until now. I really wasn't planning on buying a car until I saw this one on Facebook Marketplace in the middle of the night this past Wednesday and immediately thought about scooping it up since these cars are hard to come by in my area of rural northern Minnesota, especially with a cool spec and a price I can reasonably afford. It has Titanium Gray Metallic paint and the rare Atacama (orange) interior as well has the M66 Spaceball manual transmission. I've been wanting to get back into a manual again so this works out well. It's also equipped with the factory pop up navigation display and built in phone. I drove it 60 miles back home cautiously going highway speeds, the car runs great and the transmission shifts well, brakes work well, no major issues with vibrations going down the highway. It has 162k miles on it at time of purchase.

This car is certainly not perfect, it has pretty clearly lived a hard life. It's been passed around many times (I'm the 9th owner according to CarFax :shock: ) so there are A LOT of "somebody's been here before" problems and quirks I need to get resolved. But thankfully, I'm mechanically and electrically inclined to work on this and have the motivation and resources to bring this car back up to the level I think an R under my ownership deserves to be at. It has good bones is what I would say. Recently buying a VIDA/DICE system is going to really pay off helping me fix and maintain this thing.

The Pros:
  • Transfer case, drive shaft, and both rear CV axles were replaced within the last year/10,000 miles. The transfer case was a known good unit from a wrecked car with 70k miles. The driveshaft is almost certainly from the same car if those can't be purchased new anymore. The rear CV axles are both brand new OEM. This was one of the big deciding factors for me purchasing the car despite its flaws since this is a major job and very expensive.
  • Transmission output seal was replaced alongside the transfer case job.
  • Alternator was replaced during that time as well.
  • The paint is in good condition, no clear coat problems I can see with the exception of a small rust bubble on the bottom of the drivers A pillar.
  • Very minimal rust for being a lifelong Minnesota car.
  • No major vibrations when driving.
  • Suspension seems to be in decent condition.
  • Oil is very clean, previous owner changed it every 3k miles.
  • Engine runs smoothly, transmission shifts well. Lots of power when the turbo kicks in.
  • All of the exterior lights work.
  • Pretty much all electronics in the interior seem to work with the exception of the front passenger door listed below.
  • Supposedly has an aftermarket cat-back exhaust.
  • The car is mostly stock, just a handful of minor mods that I know of and can see. There might be more I haven't found yet.
  • Has aftermarket iPD TCV upgrade part. Poorly installed but it does have it. I'll do a better job of securing it and routing the hoses.
  • PCV was replaced 2 owners ago (within the last 3 years give or take).
  • Still has the original Volvo windshield.
  • Popup NAV display works and still has the remote control.
The Cons:
  • There is a failing wheel bearing that is very obvious when doing 40-50 mph or when taking a sharp left turn. I suspect the front left wheel bearing, already ordered the part last night. This is why I was being cautious during the drive home and have not done a hard full-throttle pull yet.
  • The clutch is very worn. It doesn't engage until the pedal reaches nearly the top of the stroke. Makes going from a stop pretty annoying having to lift off the pedal so far to get it to engage. This won't be cheap but it's necessary and is also a reason I haven't done a hard pull.
  • Codes for an O2 sensor fault. Supposedly the aftermarket exhaust does not use the rear sensor and has such been disconnected. I need to get under the car more to verify this.
  • Stored code for an over boost condition. Not sure how serious this is.
  • Air conditioning works but stops working when the car gets warm. I'm 90% sure the AC compressor clutch needs to be shimmed. My V70 had exactly the same problem and shimming was the fix for that one.
  • There are plenty of small dents all over the car. Not hail damage bad, more like the car has been door dinged an alarming number of times.
  • There is a minor damage rear end accident reported on CarFax from Jan 2025 that resulted in a broken passenger side tail light and a small indent on the bumper just under the light. The tail light has not been replaced yet so I need to get a new one.
  • There is a minor crease in the quarter panel just behind the left rear wheel and just above the bumper. This happened when the previous owner was hit by another car in a parking lot.
  • The sunroof is not parking correctly. It works fine, but when it's in the parked closed position it doesn't sit flush with the roof of the car but instead sticks up just enough that there is a very small gap between the bottom of the glass seal and the roof. I will make a thread discussing this to help solve this problem soon since I'm not sure how to fix that.
  • The interior is very dirty. The leather has grime on it in pretty much every location. It's going to take some effort to revitalize the Atacama leather to be the bright orange it's supposed to be. Right now it looks more like a darker burnt orange color. The drivers seat has failed stitching in a couple spots and the leather in the middle of the backrest is very dried out and discolored. Going to hire a good detailer in the near future and probably an upholsterer further down the line if needed.
  • The center console is busted up pretty badly just like my V70s was.
  • At some point a previous owner took the gauge cluster out, removed the clear plastic lens, and placed a small piece of black tape directly over the CEL. I think this is because of the constant O2 sensor code due to the supposed aftermarket exhaust but I still consider that to be a really sketchy thing to do. Unfortunately I didn't notice that until this morning, it's quite discrete.
  • The lid for the air filter housing is missing. My understanding from brief research is that they can be a bit fragile. I will either need to try and source a used one or just get an all new aftermarket intake.
  • Lots and lots of codes scanned with VIDA this morning. I took pictures went ahead and cleared the codes. I'll check back in with VIDA to see what codes remain after I drive the car around a bit to see what codes I need to actually worry about instead of old stored codes.
  • Minor gripe, but the shift knob is not original but instead a molded soft rubber knob that vaguely looks like the stock one. Not a big deal but I would much rather have the stitched leather one or a very similar leather aftermarket.
  • Front right window actuator has a broken clip, previous owner just got the new part in after I bought it so he will be shipping that out to me. The entire door is temporarily electrically disconnected from the rest of the car until that gets fixed.
  • Neither of the 2 keys are original R keys. Very strangely, instead of the typical P2 fob with the flip out key, both keys are cut S/V70 rubber keys that have an aftermarket P2 fob on the same key ring used for the remote functions but the flip out key is left blank and uncut. It all works as intended but it's really bulky and heavy. Why would they do it like that? Does this not have a P2 ignition in it? is there a difference in the blade between the P80 and P2? See picture.
    20260531_144710.jpg
As you can see there are plenty of things to do and probably many more little problems I have yet to discover but it should still be an interesting journey to getting this car back to being nice again. I know it would make more sense to find a nicer example but unfortunately nice ones demand a pretty significant premium and there just aren't any in my region so hey, I'll take what I can get. Here are some photos I took after bringing her home!

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Shoutout @VolvoOwl98 for inspiring me to make a thread like this!
2000 V70 SE - Bought sight unseen in Cleveland, no longer my only car. Looks identical to my profile picture
2004 S60 R - M66 "Spaceball" manual transmission, Atacama "orange" interior, Titanium Gray metallic

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VolvoOwl98
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Post by VolvoOwl98 »

That’s an awesome find! (Even with the things that need to be remedied, shouldn’t be too bad especially with some of the bigger repairs have been done recently.

I’ll always have a soft spot for the P2 chassis, nearly my entire life up until several years ago was spent in a 2002 XC70. The R variants are always so cool, and yours having a Spaceball shifter just adds to that.

I’m happy you found my thread on Saskia inspiring, and look forward seeing what you do with your new Swedish companion :)
Lifted 1998 V70XC "Saskia" - Introduction/Continuing Repair Post: viewtopic.php?t=107993
- Chassis number: 475986 (early 1998 chassis dated 01/98)
- Emission code: 4

Learning and growing all the time

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volvolugnut
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Post by volvolugnut »

That looks like a garage remodel in the background. That will be very helpful working on the new Volvo.
volvolugnut
The Fleet:
Volvo: 2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple Volvo parts cars.
Mercedes: 2001 E320, 1973 280, 1974 280C, 1989 300E, 1988 300TE, 1979 300TD, parts cars.
2009 Smart Passion
Ford: 1977 F350, 1964 F150 (2), 1938 Tudor Sedan
Farmall tractors: 1956 400 Diesel, 1946 A
John Deere 214 lawn tractor about 1977 model
And others.

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ignatz
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Post by ignatz »

Nice car!
2002 V70 2.4
2005 S60 2.5t awd
2006 S60 t5 stick shift

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rolsen11
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Post by rolsen11 »

volvolugnut wrote: 31 May 2026, 14:56 That looks like a garage remodel in the background. That will be very helpful working on the new Volvo.
volvolugnut
Sure is! Old garage was very short and not very roomy. Once that's complete I'll have a good space to wrench.
2000 V70 SE - Bought sight unseen in Cleveland, no longer my only car. Looks identical to my profile picture
2004 S60 R - M66 "Spaceball" manual transmission, Atacama "orange" interior, Titanium Gray metallic

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volvolugnut
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Post by volvolugnut »

You can never have too many tools or too much garage space!
volvolugnut
The Fleet:
Volvo: 2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple Volvo parts cars.
Mercedes: 2001 E320, 1973 280, 1974 280C, 1989 300E, 1988 300TE, 1979 300TD, parts cars.
2009 Smart Passion
Ford: 1977 F350, 1964 F150 (2), 1938 Tudor Sedan
Farmall tractors: 1956 400 Diesel, 1946 A
John Deere 214 lawn tractor about 1977 model
And others.

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rolsen11
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Post by rolsen11 »

Was able to confirm with the previous owner that the collar that connects the transmission to the angle gear was also replaced in that big service. I expected that but it was never mentioned beforehand. Hopefully that all means the AWD system doesn't need to be touched again for the life of the car.
2000 V70 SE - Bought sight unseen in Cleveland, no longer my only car. Looks identical to my profile picture
2004 S60 R - M66 "Spaceball" manual transmission, Atacama "orange" interior, Titanium Gray metallic

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erikv11
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Post by erikv11 »

Having all the AWD hardware already replaced is great, will save you some headache. You should still expect to drop the driveshaft every few years to mess with the Haldex pump and filter. This can go out without any warning light, you just have to realize AWD is not working or check codes.

Common to dismantle the air filter to put in a K&N style filter. Have not heard of the housings breaking. I suspect they went back to stock but found they lost the top. Junkyard time.

Funkiest key setup I've ever seen, curious to know what's up there. Like you said, is it a P80 cylinder?

The other achilles heel of these cars (after the angle gear) is cracked piston sleeves. This one looks to have maybe been driven hard at some point so for peace of mind I'd make sure there are no combustion gases in the coolant.
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 201k
'07 XC70, black, 205k
'07 XC70, willow green, 223k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k

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rolsen11
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Post by rolsen11 »

erikv11 wrote: 01 Jun 2026, 08:00 Having all the AWD hardware already replaced is great, will save you some headache. You should still expect to drop the driveshaft every few years to mess with the Haldex pump and filter. This can go out without any warning light, you just have to realize AWD is not working or check codes.
Good idea, I'll look into that. I doubt its ever been done. Or if it has its probably been a long time.
erikv11 wrote: 01 Jun 2026, 08:00 Common to dismantle the air filter to put in a K&N style filter. Have not heard of the housings breaking. I suspect they went back to stock but found they lost the top. Junkyard time.
That's very plausible. I gotta see if there are any junkyard Rs in my area, I kinda doubt it. If there aren't I'll either attempt to find one online for a decent price (no luck with that yet) or get an aftermarket intake.
erikv11 wrote: 01 Jun 2026, 08:00 Funkiest key setup I've ever seen, curious to know what's up there. Like you said, is it a P80 cylinder?
I dug into this a little bit yesterday. The ignition tumbler in this car has absolutely been replaced. The blank P2 fob key does fit into the ignition. The keys I have only work in the ignition. None of them work on the exterior tumblers in the driver door and the trunk. Which means the only way to unlock the car is to use the fob. My working theory is that the 2 S/V70 style keys are from whatever car the ignition came from, and then they got a couple of aftermarket P2 fobs just to program the remote control functions and didn't have them cut because they already have cut keys that work.

I need to do some research and figure out how the hell I'm going to solve this weirdness. I would really really like to have just one P2 style key fob that can unlock the doors and start the car the way it's supposed to be from factory. Maybe I need to pull an ignition and all door locks from a whole other S60 entirely. Unless it's possible to get a new ignition that matches my cars VIN (I doubt it).
erikv11 wrote: 01 Jun 2026, 08:00 The other achilles heel of these cars (after the angle gear) is cracked piston sleeves. This one looks to have maybe been driven hard at some point so for peace of mind I'd make sure there are no combustion gases in the coolant.
Good to know. How can I prevent this from happening? Being easy on it most of the time? Sounds like if this happens the engine is toast.
2000 V70 SE - Bought sight unseen in Cleveland, no longer my only car. Looks identical to my profile picture
2004 S60 R - M66 "Spaceball" manual transmission, Atacama "orange" interior, Titanium Gray metallic

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erikv11
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Post by erikv11 »

Weird about the key, thanks for details. I'll speculate the cylinder jammed (super common due to a metal tab breaking off the steering lock mechanism) and they didn't realize they could just cut off the bottom metal and dislodge the jammed, broken piece.
rolsen11 wrote: 01 Jun 2026, 12:29 ...
erikv11 wrote: 01 Jun 2026, 08:00 Common to dismantle the air filter to put in a K&N style filter. Have not heard of the housings breaking. I suspect they went back to stock but found they lost the top. Junkyard time.
That's very plausible. I gotta see if there are any junkyard Rs in my area, I kinda doubt it. If there aren't I'll either attempt to find one online for a decent price (no luck with that yet) or get an aftermarket intake.
I think the same, larger airbox came on the 2004-2007 R models and the 2005-2007 T5 models. Might help you to find one.
rolsen11 wrote: 01 Jun 2026, 12:29 ...
erikv11 wrote: 01 Jun 2026, 08:00 The other achilles heel of these cars (after the angle gear) is cracked piston sleeves. This one looks to have maybe been driven hard at some point so for peace of mind I'd make sure there are no combustion gases in the coolant.
Good to know. How can I prevent this from happening? Being easy on it most of the time? Sounds like if this happens the engine is toast.
Most people do replace the engine if the sleeves crack. There are a million posts about this problem over on Swedespeed, but I have not read most of them. It seems the main aggravators are overheating and suboptimal ignition (bad tune, too-low octane fuel, ignition timinng issues). So yeah I try to keep the engine running well and resist stomping on it all the time (booo!). I'm wondering if I should service the injectors soon, to help prevent lean ignition.
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 201k
'07 XC70, black, 205k
'07 XC70, willow green, 223k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k

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