NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
192 reportsMileage unknown · Sep 9, 2002
Equipment
VOLVO REFUSES TO ACKNOWLEDGE A DESIGN FLAW IN THE A/C EVAPORATOR. THE EVAPORATORS CHRONICALLY FAIL, LEAKING R134A INTO THE PASSENGER COMPARTMENT. I HAVE CONTACTED MANY OWNERS ON THE NET, AS WELL AS DISCUSSING THE PROBLEM WITH MASTER VOLVO MECHANIC. I WAS TOLD IT'S A VERY COMMON FAILURE WITH THIS MODEL. OWNERS ARE FORCED TO PAY …
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VOLVO REFUSES TO ACKNOWLEDGE A DESIGN FLAW IN THE A/C EVAPORATOR. THE EVAPORATORS CHRONICALLY FAIL, LEAKING R134A INTO THE PASSENGER COMPARTMENT. I HAVE CONTACTED MANY OWNERS ON THE NET, AS WELL AS DISCUSSING THE PROBLEM WITH MASTER VOLVO MECHANIC. I WAS TOLD IT'S A VERY COMMON FAILURE WITH THIS MODEL. OWNERS ARE FORCED TO PAY HIGH REPLACEMENT COST ($1200), OR ILLEGALLY CHARGE/DISCHARGE HARMFUL R134A TO RECHARGE THE SYSTEM. TYPICAL RECHARGE ONLY LASTS A FEW WEEKS DUE TO LEAKS IN THE EVAPORATOR. R134A CHEMICAL CONTAINS HARMFUL INGREDIENTS, EXPOSING THE OCCUPANTS OF THE VEHICLE TO THE LEAKING FUMES AND POSSIBLE HEALTH HAZARD.*AK
NHTSA ODI #766902
Mileage unknown · Sep 6, 2002
Service Brakes, Hydraulic
THE ABS ELECTRONIC CONTROL UNIT FAILED. THE DEALER STATED THAT THE PROBLEM WAS COMMON WITH THIS MODEL DUE TO A KNOWN DESIGN FLAW. THE CONSUMER IS SEEKING FULL REIMBURSEMENT. *YH
NHTSA ODI #567350
Mileage unknown · Aug 28, 2002
SeatsFire
AFTER STARTING THE ENGINE, I SWITCHED THE SEAT HEATER ON AND DROVE AWAY. WITHIN 2 MINUTES OF DRIVING, A SHARP PAIN DEVELOPED IN MY RIGHT BUTTOCK. WITHIN SECONDS A TRAIL OF DARK SMOKE ROSE FROM THE SAME AREA. AFTER LIFTING MY BOTTOM OFF OF THE SEAT AND REALIZING THE SMOKE WAS COMING FROM THE SEAT I SHUTOFF THE SEAT WARMER. TH…
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AFTER STARTING THE ENGINE, I SWITCHED THE SEAT HEATER ON AND DROVE AWAY. WITHIN 2 MINUTES OF DRIVING, A SHARP PAIN DEVELOPED IN MY RIGHT BUTTOCK. WITHIN SECONDS A TRAIL OF DARK SMOKE ROSE FROM THE SAME AREA. AFTER LIFTING MY BOTTOM OFF OF THE SEAT AND REALIZING THE SMOKE WAS COMING FROM THE SEAT I SHUTOFF THE SEAT WARMER. THE RESULT OF THE INCIDENT LEFT A BURN MARK ON MY PANTS AND A CIGARETTE SIZED HOLE IN MY SEAT CUSHION. I IMMEDIATELY TOOK THE VEHICLE TO THE DEALER AND AFTER INVESTIGATION I WAS INFORMED THAT THE PART WAS NOT UNDER WARRANTEE. THE COST OF THE NEW SEAT WARMER AND REPLACEMENT OF THE SEAT CUSHION WAS 770 US DOLLARS. I REFUSED TO PAY AND ASKED THE DEALER TO SIMPLY DISCONNECT THE SEAT WARMER.*AK
NHTSA ODI #766384
Mileage unknown · Aug 7, 2002
Seat BeltsCrashInjury
WHILE DRIVING AND WITHOUT WARNING INVOLVED IN A SIDE COLLISION. DRIVER'S SIDE SEAT BELT DID NOT RESTRAIN DRIVER, DRIVER SUSTAINED MAJOR BODY INJURIES. DEALER HAS BEEN NOTIFIED.*AK
NHTSA ODI #8015726
Mileage unknown · Aug 7, 2002
Air BagsCrashInjury
WHILE DRIVING 25-30 MPH AND WITHOUT WARNING INVOLVED IN A SIDE SWIPED COLLISION. UPON IMPACT, AIR BAGS NOT TO DEPLOY CONSUMER SUSTAINED MAJOR BODY INJURIES. DEALER HAS BEEN NOTIFIED HOWEVER UNABLE TO REMEDY THE PROBLEM.*AK
NHTSA ODI #8015725
Mileage unknown · Jul 24, 2002
Equipment
WHEN GOING TO GET AIR CONDITIONING SYSTEM RECHARGED, CONSUMER WAS INFORMED THAT HE NEEDED AN EVAPORATOR, ACCUMULTOR, TEMP SENSOR, EVAC AND RECHARGE, CONSUMER STATES THAT THE AIR CONDITIONER IS NOT USED TO THAT EXTENT TO REQUIRE THIS LEVEL OF REPAIRS THIS SOON. *SLC
NHTSA ODI #566865
Mileage unknown · Jul 11, 2002
Fuel System, Gasoline
THE FUEL TANK WAS OBSERVED TO BE LEAKING ON 7/8/02 AND THIS WAS CONFIRMED BY A TECHNICIAN ON 7/9/02. THE LEAKAGE OCCURS ON ONE OR MORE OF THE MOLDED BOSSES UPON WHICH THE HEAT SHIELD IS MOUNTED. MY SUSPICION IS BUILT-IN STRESSES FROM THE MOLDED BOSS, PERHAPS NOT RADIUSED PROPERLY WHERE THE BOSS JOINS THE TANK WALL. IT MAY ALS…
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THE FUEL TANK WAS OBSERVED TO BE LEAKING ON 7/8/02 AND THIS WAS CONFIRMED BY A TECHNICIAN ON 7/9/02. THE LEAKAGE OCCURS ON ONE OR MORE OF THE MOLDED BOSSES UPON WHICH THE HEAT SHIELD IS MOUNTED. MY SUSPICION IS BUILT-IN STRESSES FROM THE MOLDED BOSS, PERHAPS NOT RADIUSED PROPERLY WHERE THE BOSS JOINS THE TANK WALL. IT MAY ALSO BE A MATERIALS PROBLEM. THE TECHNICIAN ANALYZING THE PROBLEM SAID THAT THEY HAD SEEN THE SAME FAILURE ON ANOTHER 850 TANK WITHIN THE LAST 10 DAYS. IT IS ALSO POSSIBLE THAT OUR EXTREME AMBIENT HEAT MAY HAVE CAUSED A RELATIVELY INFLEXIBLE HEAT SHIELD TO STRESS THE ASSEMBLY. IT SEEMS TO BE A CRITICAL SAFETY PROBLEM, AND I AM DISAPPOINTED THAT VOLVO HAS NOT BEEN WILLING TO JOIN IN REMEDYING THIS SITUATION WITH US, AFTER CALLING IT TO THEIR ATTENTION.*AK
NHTSA ODI #764077
Mileage unknown · Jul 10, 2002
Service Brakes, Hydraulic
FAILURE OF MODULE DISENABLED THE ABS. SPORATIC FAILURE FIRST OCCURRED AT 32000 MI, BUT COMPLETE FAILURE OCCURRED AT 52,000 MILES. CAR REPAIRMAN INDICATES THAT FAILURE OF THIS MODULE IS COMMON FOR 1996-1998 VOLVOS. HE REPLACES 3-4 PER WEEK. *AK
NHTSA ODI #764033
Mileage unknown · May 19, 2002
Service Brakes, Hydraulic
THE FAILURE OF THIS COMPONENT, WHICH IN SEARCHING THE WEB IS VERY COMMON ON THE 1996 MODEL, RESULTS IN FALSE TRIGGERING OF THE ABS SYSTEM, WHICH INCREASES STOPPING DISTANCE SIGNIFICANTLY. A SEARCH OF WWW.BRICKBOARD.COM FOR 850 & ABS WILL TURN UP NUMEROUS EXAMPLES OF THIS FAILURE, WHICH IS FREQUENTLY MISDIAGNOSED BY THE DEALERS. …
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THE FAILURE OF THIS COMPONENT, WHICH IN SEARCHING THE WEB IS VERY COMMON ON THE 1996 MODEL, RESULTS IN FALSE TRIGGERING OF THE ABS SYSTEM, WHICH INCREASES STOPPING DISTANCE SIGNIFICANTLY. A SEARCH OF WWW.BRICKBOARD.COM FOR 850 & ABS WILL TURN UP NUMEROUS EXAMPLES OF THIS FAILURE, WHICH IS FREQUENTLY MISDIAGNOSED BY THE DEALERS. VOLVO KNOWS OF THE FAILURES, AND HAS NOT ADMITTED THAT IT IS A SAFETY PROBLEM. IT IS A SAFETY PROBLEM SINCE THE ABS SYSTEM IS NOT FUNCTIONING CORRECTLY, AND THE FAILURE CAUSES INCREASED STOPPING DISTANCES.*AK
NHTSA ODI #762054
Mileage unknown · Apr 18, 2002
Structure
FRONT DOOR STAY ATTACHING LUGS (6817408) BREAK WELD. WEAK DESIGN, DOOMED TO FAIL. SERVICE BULLETIN (881807) IN 1995. NEWER CARS SAME PROBLEM BODY SHOP REPAIR $150/DOOR. VOLVO SHOULD REPAIR. *AK
NHTSA ODI #760884
NHTSA investigations
6EA03008 · Fuel Tank Leaks
Opened Jun 11, 2003 · Closed Jul 28, 2004
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage
THIS ENGINEERING ANALYSIS WAS OPENED ON JUNE 11, 2003, BASED ON 54 REPORTS OF FUEL TANK LEAKS.THE SUBJECT VEHICLES WERE 1993 THROUGH 1996 MODEL YEAR (MY) 850 VEHICLES. MODEL 850 WAS ALSO PRODUCED IN MY 1997 AND WAS INCLUDED IN THIS INVESTIGATION. ANALYSIS OF THE DATA REVEALS TWO DISTINCT ISSUES. FIRST, THE 1994 THROUGH 1997 MY VEHICLES STAND OUT BY ACCOUNTING FOR 95 PERCENT OF THE REPORTED LEAKS.THESE VEHICLES SHARE THE SAME FUEL TANK DESIGN (PN 9142618). THE 1993 MY VEHICLE USES A DIFFERENT FUEL TANK DESIGN (PN 9141101).SECONDLY, THE FAILURES OCCURRED PREDOMINANTLY IN HOT CLIMATES, E.G., CALIFORNIA, ARIZONA, TEXAS, FLORIDA, GEORGIA, LOUISIANA, ETC.TESTING OF FUEL TANKS FROM CONSUMER VEHICLES AT THE VEHICLE RESEARCH AND TEST CENTER CONFIRMED LEAKS THROUGH CRACKS IN THE FUEL TANK WALL AT A HEAT SHIELD MOUNTING ATTACHMENT IN THE 1994 THROUGH 1997 MY FUEL TANKS (PN9142618). DETAILS OF THE TESTS ARE AVAILABLE IN TEST REPORT VRTC-DCD3060.VOLVO WILL CONDUCT A SAFETY RECALL ON ALL MY 1994 THROUGH 1997 VEHICLES ORIGINALLY SOLD OR REGISTERED IN THE FOLLOWING 17 HOT STATES: CA, AZ, NM, TX, LA, MS, AL, GA, SC, FL, NC, TN, AR, OK, UT, NV, AND HI.ALL 1994 THROUGH 1997 MY VEHICLES IN ALL OTHER STATES WILL BE REMEDIED UNDER A SERVICE CAMPAIGN.THE REMEDY FOR BOTH THE RECALL AND SERVICE CAMPAIGN IS TO INSTALL A NEW BUSHING AT EACH HEAT SHIELD ATTACHMENT POINT (3 PER TANK).ALSO, ALL TANKS (VEHICLES IN ALL STATES) WILL BE INSPECTED FOR FUEL SEEPAGE AT THE HEAT SHIELD ATTACHMENT POINTS AND VOLVO WILL REPLACE ANY TANK SHOWING SIGNS OF FUEL SEEPAGE.THE NEW BUSHINGS WILL PREVENT HEAT SHIELD STRESSES FROM BEING TRANSFERRED TO THE THREE HEAT SHIELD MOUNTING ATTACHMENTS ON THE FUEL TANK.THE SAFETY RECALL IS FILED UNDER NHTSA SAFETY RECALL NUMBER 04V368.THIS INVESTIGATION IS CLOSED.
PE03003 · Fuel Tank Leaks
Opened Jan 16, 2003 · Closed Jun 11, 2003
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly
THE OFFICE OF DEFECTS INVESTIGATION OPENED THISINVESTIGATION ON JANUARY 16, 2003.THE BASIS FOR OPENING THE INVESTIGATION WAS 15 CONSUMER REPORTS ALLEGING GASOLINE LEAKING FROM THE FUEL STORAGE TANK.VOLVO PROVIDED 43 ADDITIONAL REPORTS IN ITS RESPONSE TO THE PRELIMINARY EVALUATION, 4 OF WHICH WERE DUPLICATES OF THE 15 ODI REPORTS. THIS INVESTIGATION HAS BEEN UPGRADED FOR FURTHER STUDY.
EA02019 · Seat Fires
Opened Aug 22, 2002 · Closed Dec 18, 2002
Status: closed (inferred from source dates) · Electrical System; Seats:front Assembly:seat Heater/cooler
VOLVO IS CONDUCTING A SAFETY RECALL BASED ON ITS ANALYSIS OF COMPLAINTS AND TECHNICAL INFORMATION DEVELOPED DURING ITS INVESTIGATION.VOLVO'SSURVEY OF VEHICLES ROUTINELY BROUGHT IN FOR MAINTENANCE AT EAST-COAST DEALERSHIPS PRODUCED EVIDENCE THAT BARE METAL WIRES (THAT PROVIDE SUPPORT FOR THE SEAT BOTTOM) CAN CONTACT THE THERMOSTAT AND ELECTRICAL WIRESIN OR BENEATH THE SEAT CUSHION.THIS CAN RESULT IN AN ELECTRICAL SHORT.VOLVO CONFIRMED IN TESTING THAT IF SUCH A CONDITION IS PRESENT, THE SHORT TO THE WIRE SEAT SUPPORT COULD CAUSE BURNING OF THE SEAT CUSHION WITHOUT ACTIVATING (OPENING) THE SEAT HEATER FUSE.VOLVO WILL REPLACE THE ENTIRE THERMOSTAT ASSEMBLY WITH AN ELECTRONIC TIMER DELAY UNIT.
Additional source detail variants (2)
Electrical System
VOLVO IS CONDUCTING A SAFETY RECALL BASED ON ITS ANALYSIS OF COMPLAINTS AND TECHNICAL INFORMATION DEVELOPED DURING ITS INVESTIGATION.VOLVO'SSURVEY OF VEHICLES ROUTINELY BROUGHT IN FOR MAINTENANCE AT EAST-COAST DEALERSHIPS PRODUCED EVIDENCE THAT BARE METAL WIRES (THAT PROVIDE SUPPORT FOR THE SEAT BOTTOM) CAN CONTACT THE THERMOSTAT AND ELECTRICAL WIRESIN OR BENEATH THE SEAT CUSHION.THIS CAN RESULT IN AN ELECTRICAL SHORT.VOLVO CONFIRMED IN TESTING THAT IF SUCH A CONDITION IS PRESENT, THE SHORT TO THE WIRE SEAT SUPPORT COULD CAUSE BURNING OF THE SEAT CUSHION WITHOUT ACTIVATING (OPENING) THE SEAT HEATER FUSE.VOLVO WILL REPLACE THE ENTIRE THERMOSTAT ASSEMBLY WITH AN ELECTRONIC TIMER DELAY UNIT.
Seats:front Assembly:seat Heater/cooler
VOLVO IS CONDUCTING A SAFETY RECALL BASED ON ITS ANALYSIS OF COMPLAINTS AND TECHNICAL INFORMATION DEVELOPED DURING ITS INVESTIGATION.VOLVO'SSURVEY OF VEHICLES ROUTINELY BROUGHT IN FOR MAINTENANCE AT EAST-COAST DEALERSHIPS PRODUCED EVIDENCE THAT BARE METAL WIRES (THAT PROVIDE SUPPORT FOR THE SEAT BOTTOM) CAN CONTACT THE THERMOSTAT AND ELECTRICAL WIRESIN OR BENEATH THE SEAT CUSHION.THIS CAN RESULT IN AN ELECTRICAL SHORT.VOLVO CONFIRMED IN TESTING THAT IF SUCH A CONDITION IS PRESENT, THE SHORT TO THE WIRE SEAT SUPPORT COULD CAUSE BURNING OF THE SEAT CUSHION WITHOUT ACTIVATING (OPENING) THE SEAT HEATER FUSE.VOLVO WILL REPLACE THE ENTIRE THERMOSTAT ASSEMBLY WITH AN ELECTRONIC TIMER DELAY UNIT.
PE02029 · Passenger Compartment Fires
Opened Mar 7, 2002 · Closed Aug 22, 2002
Status: closed (inferred from source dates) · Electrical System
No summary supplied.
PE99040 · Inadvertent Side Air Bag Deployment
Opened Jun 7, 1999 · Closed Oct 27, 1999
Status: closed (inferred from source dates) · Air Bags:side/window
No summary supplied.
PE97045 · Engine Compartment Fire
Opened Oct 23, 1997 · Closed Feb 13, 1998
Status: closed (inferred from source dates) · Engine And Engine Cooling
ODI HAS RECEIVED FOUR OWNER COMPLAINTS OF VOLVO 850 ENGINE COMPARTMENT FIRES, ALL INVOLVING 1996 MODEL YEAR VEHICLES.TABLE 1 SHOWS THE DISTRIBUTION OF FIRE INCIDENTS KNOWN TO ODI AND VOLVO BY MODEL YEAR AND INCIDENT YEAR FOR ALL 1993-97 VOLVO 850 VEHICLES.VOLVO HAS CLASSIFIED MOST OF THE FIRES AS OCCURRING FROM UNDETERMINED CAUSES.IN THOSE FEW CASES WHERE PROBABLE OR POSSIBLE CAUSES WERE IDENTIFIED, NO COMMON DEFECT PATTERN OR TREND HAS BEEN IDENTIFIED.THIS INVESTIGATION IS CLOSED, BUT ODI WILL CONTINUE TO MONITOR THE ISSUE THROUGH 11998 WITH QUARTERLY REPORTS FROM VOLVO.
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