I purchased a used 2001 S40 a little less than a year ago. It came with only one key (the previous owner bought it from a car auction and they only got a key). I know nothing about about Volvos, and this is the first one I have. Well, my step daughter broke the ring on the key. So, I.. drilled a couple holes in the key to put in a new ring. You all probably know what happens next.. the car won't start and comes up with the immobilization warning light. No problem, get a new key reprogrammed key right?
No exactly, despite having my VIN and proof of ownership, a key cannot be made unless they have the car in the shop. That would be fine, if it weren't for the fact that the closest Volvo shops are 3 hours away, in Seattle (and they don't like to respond to petty requests like mine), and one in Boise (who did respond) but is six hours away.

There have to be other options out there, but I have no idea where to look.

 

A key can be made without the car present. VIN and proof of ownership should be all that is needed. (the dealer has made at least a hundred for my shop when customers requested them, then I would program the car with my VIDA subscription)
The key and the car have to be in the same place to be able to program the car to accept the signal from the new key.
That requires a VIDA subscription and a DICE unit. Anyone can purchase a VIDA subscription from volvotechinfo.com
But I would not recommend that route for the average car driver.

A possible option is the company listed in the thread below - but a DICE is still needed. I don't know if they can do s40 keys

https://www.swedespeed.com/threads/j.../#post-8049664