Used car guide

2002 Volvo S40: common problems and what to check

What gets flagged at MOT on 2002 Volvo S40s, from 344 tests in 2025, plus known faults and what to look at before you buy one.

Small sample: only 344 of these were MOT tested in 2025, so treat the percentages as rough. The known faults below don't depend on it.

344MOT tests in 2025
53%pass first time (all 2002 cars: 60%)
4,300typical miles a year
2.7×the usual rate for sidelights

What stands out

Parts flagged at MOT more often on 2002 Volvo S40s than on all cars registered in 2002.

  • Sidelights2.7× usual
    Volvo S40
    16% All 2002 cars
    5.9%

    Failed outright at MOT: 13.1%, against 5.1% of all 2002 cars. The rest were advisories or minor defects.

    Rough price £10–£80 our estimate

    At the viewing: Ask a friend to check every light while you work the switches: indicators, brake lights, fog lights and reversing lights.

  • Number plate lights1.9× usual
    Volvo S40
    14.5% All 2002 cars
    7.5%

    Failed outright at MOT: 4.9%, against 1.9% of all 2002 cars. The rest were advisories or minor defects.

    Rough price £5–£40 our estimate

    At the viewing: Check the number plate lights work and the plates are clean and legal.

  • Ball joint dust cover2.5× usual
    Volvo S40
    10.8% All 2002 cars
    4.3%

    Failed outright at MOT: 4.4%, against 1.5% of all 2002 cars. The rest were advisories or minor defects.

    Rough price £60–£150 (one joint) ClickMechanic

    At the viewing: Listen for knocking over bumps and check the rubber boots behind the wheels aren't split.

By area

The share of 2002 Volvo S40 MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

  • Brakes
    51% of testsRough price £150–£350

    At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

  • Suspension
    48% of testsRough price £120–£400

    At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

  • Lights and electrics
    44% of testsRough price £10–£80

    At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

  • Tyres
    29% of testsRough price £70–£150

    At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

  • Wipers, windscreen and mirrors
    14% of testsRough price £15–£250

    At the viewing: Check for chips in the driver's view, and test the wipers and washers.

  • Oil and fluid leaks
    11% of testsRough price £80–£600

    At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

Looking at a Volvo S40?

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Other years

YearMOT testsMost flagged
20121,220Suspension 37%
20111,333Suspension 43%
20101,691Suspension 44%
20092,114Suspension 44%
20082,447Suspension 47%
20071,500Suspension 50%
20061,338Suspension 48%
20051,142Suspension 52%
2004910Suspension 47%
2003515Suspension 48%
2001264Suspension 51%
2000160Suspension 46%
1999101Lights and electrics 47%
1998102Suspension 53%

Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2002 Volvo S40s registered in 2002. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score