Hi , I am actually new to this forum , I wonder if somebody could assist ,

My 2004 S60 2.0 T with 108000kms , 2 days ago , I Got the "Brake Failure Stop Message" I stopped & turned the engine off & checked everything , brake fluid levels etc were 100% . When I start the car again the message changed to "Engine System Service required" & Brake , ABS Lights on & Speedometer stops working when this message comes up . I am taking the car to a Volvo specialist tomorrow to have the fault codes read. What concerns me is that I been researching this message & its seems to point to the ABS Control Module which costs an arm & a leg to replace at the dealer prices . Although I am not sure if its the module on my car until it gets scanned tomorrow , can this message come up due to some other component failing other that the ABS module ?? On my car the message came up just after I drove over a small pothole & I 'm not sure if something has come loose. The other thing I would wish someone could shed some light on is whether the ABS Module on my car is repairable or not , I have heard of some of them being repaired quiet efficiently , my vehicle has DSTC as well , your advice & assistace will be highly appreciated.. Regards Trevor

 

How old is your battery? Sometimes if the battery doesn't hold enough charge it will trip the computer.

Reason i'm saying that is because my 2004 S60 non-turbo had the same problem and turns out the battery was 1 volt off.

 

Thx for the post , I have just gone to check my car after reading yr post , funny enough it still has the Volvo Battery with 2004 stamped on it , So I'm definitely going to have the battery tested first before anything else..

Will give some feedback once I have tested the battery..

 

Hi ,,

Had my S60's battery tested , turns out its only seems to charge up to 8.5 volts , should be 13.8 . Its also the same Volvo battery since 2004.
The alternator was also tested & checked out fine --

Will update once I have installed the new Battery ...

 

Hi ,,
Had the battery replaced today , message went away for a short while but lights & brake failure message came on again after a short drive . Guess I'm going get the faults read at a volvo specialist on Monday & work from that diagnosis.

Tks

Trevor

 

when was the last time you had your brakes done? Check all your brakes and replace if needed or clean them up esp. the sensors w/c could have been dislodged when u hit a pot hole.
ABS modules are repairable. Check out Midwest-abs.com - that's Matty Moo's site and some MVS forum members say his job is excellent.

 

Hey I have a volvo xc90 and have been having similiar issues with the Brake System Failure and similar lights and gauges. Did you ever narrow it down?

My vehicle kept doing this for about 4 weeks and finally would not start. It had communication errors in about every module possible. But now it is not doing it after all message were cleared about 3 days ago.

 

Hi there , I have managed to narrow it down after much diagnosis , however my car always started & ran perfectly well although the " Brake Failure " message was there & the speedometer stopped as well . Diagnosis at various Volvo specialists showed different fault codes & each time they cleared it , the messages came back after a short drive . I decided to tinker on my own & found that I could replicate the error message each time I tapped the Plug on the ABS - Module , the message continuously changed from brake failure to " system service required " . So I bit the Bullet & removed the ABS module , as I have read on this forum & various other forums that the pins on the module do suffer some dry joints , I am in the I.T business so soldering is not totally new to me . After very carefully removing the plastic cover off the module ( this took a while ) I could see the pins where the main connector plugs in , however on my car ( 2004 with traction control ) there is no solder used at all at the factory , the pins were of the push-in type , where the pins just pushed into holes on the board to make contact . The pins are very close to each - other so I was a bit wary about soldering straight away . I used a fine tip flat-head screwdriver & bent the pins a little, forcing them to connect on the board , be careful not to damage or scratch the board. After connecting all up "brake failiure" message was gone , the speedo worked however the " engine system service required" message still remained , but also went away after a long drive . Its been a month now & my S60 is running like clockwork - not a single error - I could post some pics & diagrams on what I did if u want ... Rgds Trevor

 

What is the w for in the gear box for a 2004 volvo S60 2.4 Sedan?
just purchased a 2004 s60 2.4 i noticed that there is a w in the gear box i pushed it in but nothing happen what is the button for

 

Hi , This is definitely an Auto - Tranny , the W - switch activates winter mode , which means the transmission will actually start in 3rd gear to reduce wheel-spin in winter weather .

If operating under normal weather conditions you don't need to activate the w- switch & put the tranmission under stress .

Tks Trevor

 

Trevor,
Oh my god! I, too, have a 2004 Volvo S60. I had THE SAME problem as you did! It happened while I was going 60 mph on the highway on my way to work. First I got an error msg that the ABS was out. Then I got the "Brake System Failure-stop care safely" message. The the "System Service" message. I turned off the car, left it off for a while, turned it back on and the "System" message went away but the brake failure message has not. In addition, the BRAKE (in red) is lit up (not Park Brake, just Brake).
Since my car is still stopping (I drove 45 minutes to work!), I will get the codes read and bring this string to the mechanic when I bring it down.

 

Hey so I have the 2004 s60 2.5t and the previous owner ran into a curb.. ripped the front wheels off etc.. to make the story short- I now have a Volvo back on wheels and driving.. All the lights like ABS, BRAKE, YELLOW TRIANGLE, check Engine are on .... Everyone keeps talking about the abs module and ive located something under the hood that looks like an abs module.. it is around the lower part of the intake i believe.. and its missing the second plastic piece that covers it.. im guessing after the accident the plastic piece was cracked .. can anyone tell me what im dealing with here? PLEASE!

 

Hi There ,, Your issues are definitely related to the ABS Module , it is located under the vehicles airbox . It should have a factory sealed plastic cover on it at all times . You mentioned that the cover on your unit is missing & may have come come off during the accident , but dont panic yet there are many alternate routes here & you dont have to get the unit replaced at the Dealer for ridiculous amounts of cash . I would first remove the unit (its has 3 x torx bolts on attached ) if the board has been exposed to dust , etc , please very carefully clean off with small paint brush , now you can bolt the unit back on but do not tighten the bolts straight away as you will need to remove it again after testing so you can make a plan to cover the board. After bolting the unit back , secure the connector plug on (this must be secure) . Start vehicle & check if brake failure message is gone , if not you can try this:

Switch off vehicle & go back under the hood , try use a small spacer in between the connector plug & the base of the ABS Unit ( I first used a credit card folded in half & forced it in between the plug & the base . You see the point of failure on these units are the pins not making contact on the board , forcing a spacer in between the plug & base bends the pins a little forcing them to make contact. Test the vehicle again , if the brake failure message is gone , then the pins were at fault , remember the brake warning light , Engine system service & yellow triangle may only disappear after a short drive , but if the pins are making contact the brake failure message should not come on ..at all.

Remember this is just a test & a quick -fix , once you are sure the pins were at fault , you will need to remove it again & solder / permanently secure the pins , but perform these steps first & post your results here on this forum , I will then send you some pics on the permanent fix . Also please do not drive around with the board exposed to water etc , please cover it up properly so water cannot get in .

Note , that the braking system on these Volvos still always work fine even if this message is up .

Regards

Trevor

Rgds

Trevor

 

Whatever you do, unless you are REALLY experienced, do not touch the ABS module!! I've heard that they are "coded" to your car and to have them fixed - i.e.- YOUR particular ABS module reconstructed - costs about $375 (according to repair shops that I have contacted - including labor) but if you mess it up somehow, you'll need a new one and that can be upwards of $1000-$2000.
Can't you just go get the codes read?

 

Would you please post pics and diagrams of what you did to fix your car?

 

Hello I'm new and I need help
I have an s60 volvo 2004
My break failure senor came on along with my abs senor. Check engine light and air bag light.
My father put break fluid and my break failure came on again. Should I just change my breaks??

 

I need help on my s60 volvo 2.5 2004
Break failure

 

I have the same problem I my 2004 S60. I have repaired a abs module on a 2002 Avalanche however with that ABS module it was clear where the the case halves met and where I had to cut it open. The Volvo module had no seem and I had read too many websites that said they were not repairable. Please help. Picture would be great. I had the module out of the car but it didn't ever occur to me that the pins could be the problem.

 

Can somebody tell us the steps to follow when removing the S60 2.0T 2004 ABS control module....

 

Hi - There , I discovered after trial & error , that the module on the 2004 models are not repairable & there is no real fix for these , However there is still another route apart from buying a new unit @ 15 grand from the dealership . I got mine replaced with used a unit from a breaker , this was done by a local Volvo Specialist ( Not the DealerShip) . After replacing the unit with a used one , Speedo-meter etc will start working but you will get other errors on the OBC , like " Skid control Service required " The vehicle will need to be hooked up to Volvo Vidas online system & have the software on the new abs -unit updated with your cars VIN - Number .. etc , this was done on my car by my local guy very easily , cost me less than quarter of what the dealership quoted incl labour . This was done almost 7 months ago , my car is perfect never had another Brake failure message since . So in short the module can be replaced with a used one at a reasonable cost so long as the software is updated therafter ...