2004 Volvo S80 problems, complaints & recalls
Most-reported problem areas: Fuel/Propulsion System (13) · Suspension (4) · Steering:linkages (3)
🧭 Reliability snapshot
Compared against other Volvo S80 model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
41 NHTSA complaints that reported an odometer reading.
Safety recalls (2)
Air Bags:frontal:driver Side:inflator Module 2021-09-30 · campaign 21V766000 · 259,383 vehicles
Defect: Volvo Car USA, LLC (Volvo Car) is recalling certain 2001-2006 S80 and 2001-2009 S60 vehicles. The driver's air bag inflator may explode during deployment, due to propellant degradation occurring after long-term exposure to high absolute humidity, high temperatures, and high temperature cycling.
Risk: An inflator explosion may result in sharp metal fragments striking the driver or other occupants, resulting in serious injury or death.
Fix: Dealers will replace the driver's air bag, free of charge. Owner notification letters were mailed November 29, 2021. Owners may contact Volvo Car customer service at 1-800-458-1552. Volvo's number for this recall is R10125.
Equipment:electrical:navigational System(Global Positioning System) 2010-11-08 · campaign 10V566000 · 416 vehicles
Defect: VOLVO IS RECALLING CERTAIN VEHICLES EQUIPPED WITH GARMIN 760 PORTABLE GLOBAL POSITIONING SYSTEM (GPS) UNITS BECAUSE THE BATTERIES ON THOSE UNITS MAY OVERHEAT.
Risk: AN OVERHEATED BATTERY COULD LEAD TO A FIRE.
Fix: 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.
Service bulletins (190)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Engine 2026-04-23 · 35526.1.8 · Service Bulletin/Repair Instructions
this is a technical journal: text plus 2 pdfs and 1 .png oil consumption test. perform the test. follow service procedure description and service sections updated to clarify that vehicle reports are not required.
Unknown Or Other 2026-04-07 · 37809.1.1 · Service Bulletin/Repair Instructions
this is a tj text only - the purpose of this tj is to be a master reference list to easily identify any components that are on prior approval. this tj will be regularily updated as items are added or removed from prior approval. current items under prior approval are listed in the "service" sec
Unknown Or Other 2025-12-06 · 19245 · Service Bulletin/Repair Instructions
this is a technical journal. vehicle type and platform identification.
Exterior Lighting 2025-04-10 · 8501 · Service Bulletin/Repair Instructions
this is a technical journal: remote connection, bomgar application. before joining a remote session: •connect a suitable battery maintainer/charger and verify that the battery voltage indicated in vida is between 12.5v and 14.9v. •connect to the vehicle over a wired connection using a voe
Unknown Or Other 2025-02-21 · S10303 · Service Campaign
volvo cars usa llc and volvo car canada ltd on behalf of the volvo car corporation has decided to launch service action s10303 on certain model year 2025 ex90 vehicles. volvo car investigations have identified that there is a pairing issue with the key fob. as a result, there is a possibil
Unknown Or Other 2025-02-13 · S10303 · Service Campaign
volvo cars usa llc and volvo car canada ltd on behalf of the volvo car corporation has decided to launch service action s10303 on certain model year 2025 ex90 vehicles. volvo car investigations have identified that there is a pairing issue with the key fob. as a result, there is a possibil
Showing the 6 most recent of 190 bulletins. Search all of them free at nhtsa.gov.
What owners report
2023-01-01 · Unknown Or Other“both of the key fobs i have are broken in that the key won't lock straight out or stay folded into the fob. the weight of the plastic fob alone frequently causes the key to twist backwards if the road is bumpy or uneven, which kills the engine and makes it extremely difficult to steer to safety without power steering. the first time this happened t…”
2020-11-18 · Electrical System“on 11/17/2020 was driving to pick up decal for my car and i got a message that read a check airbags i didn't have any reading on my gages turn signal for right turn stay lit up not brinking just on , when i stopped and went in building to get decal came back to car started it my gages came back which was glad they were working but …”
2020-05-25 · Fuel/Propulsion System · 190,000 mi“after noticing a very acute smell of gas i took the vehicle in for inspection. the mechanic advise that i had a fuel leak in my 2004 volvo s 80 . thats could have been a serious problem and that the car is not driveable in this condition. …”
2017-06-22 · Fuel/Propulsion System · 92,000 mi“strong odor of gas outside of car. recall on similiar cars but not in this area. known issue by volvo but will not repair at no cost as it is outside of the 10 year extended warranty even though car does not have 150000 miles on. fire hazard and should be for all cars of this year and make but offer little if any help.…”
2017-04-19 · Fuel/Propulsion System“tl* the contact owns a 2004 volvo s80. on several occasions, the contact smelled fuel coming from the garage. upon checking underneath the vehicle, the odor became stronger. the vehicle was taken to an independent mechanic who diagnosed that a fuel leak originated from the top of the fuel tank. the fuel pump needed to be replaced. the vehicle was n…”
2017-04-17 · Fuel/Propulsion System · 19,000 mi“tl* the contact owns a 2004 volvo s80. the contact stated that he smelled fuel around the vehicle. upon inspection, the contact noticed fuel had leaked out of the top of the fuel pump. the vehicle was not taken to a dealer. the vehicle was not diagnosed or repaired. the manufacturer was not made aware of the failure. the approximate failure mileage…”
2017-02-09 · Fuel/Propulsion System · 114,800 mi“the car is putting forth a strong odor of gasoline. this was first noticed a couple of weeks ago but was put down to having just filled the tank. the problem has progressed to the point where you can smell gas 20 feet away from the car. we are not allowing our daughter to drive the car as it is an extreme fire hazard. i had the same issue with anot…”
2016-09-06 · Suspension · 157,000 mi“tl* the contact owns a 2004 volvo s80. while driving approximately 45 mph, the vehicle lost acceleration. the contact pulled the vehicle over in a parking lot and noticed that the front driver side axle was hanging. the contact stated that the same failure occurred two other times. the vehicle was repaired, but the control arm kept fracturing. the …”
2016-08-18 · Suspension · 101,000 mi“purchased a 2004 volvo s80 in "mint condition" from a used car dealership (good reputation).three (3) months later the transmission started the famous volvo "slip, slide, away".. it rides like a rock, i fell every crack, grain of sand in the road. i replaced the struts, coil springs, lower control arms and other suspensions parts but to no avail im…”
2016-07-24 · Fuel/Propulsion System · 98,635 mi“shortly after moving to north carolina, i began to smell fuel. i first thought that it was the gas cap and replaced it. the smell continued to grow stronger and stronger, to the point i could not keep it parked in my garage in my townhome due to the smell of gas which would permeate the entire house. i also noticed during this time a substantial…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.